Customizable respiratory mask

ABSTRACT

A customizable mask including a conforming seal is configured to utilize the physical process of granular jamming to enable it to adapt to a wide range of facial geometries. The mask may include a frame having a perimeter and a conduit connection, a conforming seal positioned along the perimeter of the frame; the conforming seal may include a sealing surface and a connecting surface, the connecting surface configured to mate with the perimeter of the frame, and the sealing surface configured to conform to a users&#39; face. The conforming seal may further include an outer casing, granular material contained within the outer casing, and a vacuum connection. The mask may also include a similarly configured conforming frame. Further disclosed are methods of forming such masks.

INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

Any and all applications for which a foreign or domestic priority claimis made are hereby incorporated by reference and made a part of thepresent disclosure.

BACKGROUND

Technical Field

The present embodiments relate to respiratory masks, including, forexample, customizable respiratory masks.

Description of the Related Art

Respiratory masks are used for a variety of different therapies,including but not limited to non-invasive ventilation (NIV), oxygentherapy and continuous positive airway pressure (CPAP), for thetreatment of various respiratory conditions. Many of these respiratorytherapies require that a substantially airtight seal is achieved betweena mask and a user. Due to the range of differing facial geometries inthe population, it can be difficult to achieve a desired seal as aresult of the mask geometry not matching the geometry of a user's face.It is common to apply substantial forces to a mask and user's face in anattempt to overcome any differences in geometry, and achieve a seal. Theapplication of forces to a mask and thus a user's face can causediscomfort as well as injuries to the user and not always successful atattaining satisfactory leak rates.

For example, FIGS. 1 and 2 illustrate skin sores caused by existingrespiratory masks. For a respiratory mask to be used in the provision ofrespiratory therapies such as NIV or CPAP the patient must be breathingspontaneously. In some cases, the patient is not lucid and thus not ableto indicate discomfort or pain that may precede such injuries.

BRIEF SUMMARY

An aspect of at least one of the embodiments disclosed herein includesthe realization that patient comfort can be improved and patientinjuries caused by masks can be reduced by configuring a mask foradjustment of mask contours for accommodating faces that have differentshapes and retaining the adjusted shape. For example, in someembodiments, a respiratory mask can include a jamming-enabled portion inat least one of a facial seal portion and/or a frame portion thereof.Such a mask, in some embodiments, can reduce the number of leaks and/orthe leak rate to acceptable magnitudes or eliminate leaks altogether,and can also reduce forces on the user's skin (“skin pressure”), inparticular areas of the face where the skin is thin such as the nasalbridge, for example.

Designing such masks presents several challenges, includingaccommodating differently sized and shaped faces, as well as minimizingthe force of contact between the seal and the corresponding portions ofeach different user's face. Ideally, a mask will not leak with very lowskin pressure. Leaks will occur, however, where the skin pressure isinsufficient to counter the gaseous pressure differential between theinside and outside of the mask. Thus, when unacceptable leaking is foundusing a typical mask, the force on the entire mask (e.g., by way of astrap) is typically increased until leaks are reduced to an acceptablelevel or eliminated. However, such additional force also increases theforce of contact between the seal and the user's face (skin pressure) atlocations where no leaking occurred, thereby generating unnecessarilyhigher forces at some locations, which can cause discomfort and/orinjury.

FIGS. 1 and 2 illustrate facial skin injuries suffered by patients whowore respiratory masks while receiving medical care. FIG. 1 illustratesa more generalized, inverted U-shaped injury 10 extending from thepatient's cheeks and up and over the bridge of the nose. As shown inFIG. 1, the injury 10 includes larger regions 12, 14 lower down on theuser's face and another larger portion 16 on the bridge of the patient'snose. Additionally, there are thinner, smaller regions 18, 20 lower downon the user's face, between the nose bridge injury area 16 and the lowerlarger portions 12, 14. As such, it appears that the mask causing thisinjury generated uneven forces around the patient's cheeks and nosebridge.

FIG. 2 illustrates a very localized injury 22 appearing only on thebridge of the nose of the patient. More severe injuries, such as thatillustrated in FIG. 2, are more common in areas of the face where theskin is thin, i.e. where bone is close to skin i.e. the nasal bridge.These are the areas of the face that can experience the highest loadsdue to over tightening the headgear straps of the mask system. Excessiveskin pressure can restrict blood flow, thereby starving the skin tissueof oxygen and nutrients and accelerating breakdown of the skin tissue.

With reference to FIGS. 2a -2 c, the creation of leaks, discomfort,and/or disadvantages noted above can result from a sequence of eventsdescribed below. For example, with reference to FIG. 2a , a mask 30 caninclude a frame 32 and a seal 34. The frame 32 and seal 34 can beattached to a user's face with straps 31, 33, adjusted to achieve abalance of comfort and leak rate, for example, the minimum forcesrequired to achieve either no leaks or an acceptable leak rate.

During such a process, after a first attempt to fit the mask 30 on thepatient's face, a leak can form anywhere along the seal 34, for example,in an area adjacent to the user's nose 36 and in the vicinity of auser's eye 38. Such a leak, for example, can allow air 42 from withinthe mask 30 to pass through a space between seal 34 and the patient'sface, thereby directing the air 42 towards the patient's face, andsometimes towards the user's eye 38. Additionally, it is possible thatair 42 leaking as such, can occur on only one side of the mask 30, forexample, only on the patient's left side, as illustrated in FIG. 2 a.

FIG. 2b illustrates a recessed contour 46 on the patient's face whichcan be considered the cause of the leak of the air 42. For example, therecess 46 can be a crease, fold, or line on the patient's face and thus,in this example, forms an open “leak zone.”

In the sectional view of FIG. 2c , the leak zone 46 appears as a gapbetween the outer surface of the seal 34 and the patient's face 40,where air 42 from the inside of the mask 30 leaks through the leak zone46, and outwardly from the mask 30.

In some circumstances, when such a leak occurs, a patient or healthcareworker may attempt to tighten the upper 31 and lower 33 straps on theleft side of the patient, to thereby generate additional forces toreduce the size or eliminate the leak zone 46. Such asymmetrictightening may successfully reduce or eliminate such leaking, but mayalso cause unintended consequences.

For example, such asymmetrical tightening can result in unnecessaryforces applied to the entire left hand side of the patient's face inorder to fix one small region of a leak. Such asymmetric tightening canalso unbalance the seal between the seal 34 of the mask and thepatient's face, for example, between the left and right sides of thepatient's face, such that it induces a leak in another area altogether.Such can be the beginning of a series of asymmetric tightenings toovercome leaks. Further, such repeated retightening of a mask caneventually lead to discomfort for the user and/or injury, such as thosedescribed above with reference to FIGS. 1 and 2.

An aspect of at least one of the embodiments disclosed herein includesthe realization that such injuries are sometimes caused by tightening ofa mask with the strap force, for example, on associated head straps, toform an effective seal between a patient's face and a mask which doesnot well-match the contours of the patient's face. Due to thevariability of shapes and sizes of patient's faces, uneven skin pressurepoints can be generated, thereby causing skin sores and injuries ofdifferent shapes and sizes. Additionally, patients who are semi lucidand require respiratory assistance, such as with non-invasiveventilation (NIV) using a respiratory mask, cannot provide feedback ondiscomfort or pain during the mask fitting process. A nurse or clinicianwho is fitting a respiratory mask to such a patient, is unable to tellhow tight the fit is.

An aspect of at least one of the embodiments disclosed herein includesthe realization that by providing a respiratory mask with adjustabilityin at least one of an orientation of a sealing face and a frame portion,as well as the structure and functionality for retaining the frameand/or sealing face in an adjusted, state can help reduce patientdiscomfort and/or injury and reduce leak to an acceptable level.

By contrast, some known mask designs, in order to be fitted onto theface of a patient, are sometimes pressed or squeezed so as to achievethe desired seal along a user's cheek. For example, patients with largernose bridges and longer or “pointy” faces, may require a mask to bepinched transverse to a vertical axis (e.g., the sides of the mask arerotated about a vertical axis), to cause the sides of the mask to betterfollow the patient's cheeks. This movement can be referred to as“clam-shelling.” However, some known masks are made from resilientmaterials. Thus, when a mask is pinched in the “clam shelling” movement,the frame of the mask itself acts like a spring, storing elastic energy.In order to retain the mask in such a shape, head straps are used toresist the force of the spring forces generated by the mask frame.Similarly, mask seals are often made in a resilient structure, whichalso store some energy like a spring. Thus, the straps for retainingsuch known masks also must resist these forces as well.

An aspect of at least one of the embodiments disclosed herein includesthe realization that providing for a structural and/or contouradjustability of a mask frame and/or seal can reduce or eliminate therequirement that head straps resist the stored spring energy in the maskor seal, and thereby reduce the overall required tension of head strapsfor holding a mask properly in sealing engagement with the face of apatient.

Thus in some embodiments, a customizable mask can include a mask frameand seal assembly configured to extend around a respiratory orifice of apatient, such as a nose and/or mouth. The frame can include a perimeterwith a seal portion extending along the perimeter of the frame. Theframe can also include a conduit connection which can be configured forconnection to a respiratory apparatus, such as apparatuses forventilation, oxygen therapy, and/or continuous positive airway pressure(CPAP). The seal portion can include a connecting surface and a sealingface, the connecting surface being configured to mate with the perimeterof the frame. The sealing face can be configured to form a seal withskin of a patient's face. At least one of the frame and seal portionscan be fixable in a plurality of different configurations.

In some embodiments, at least one of the frame and seal portionsincludes a granular jamming portion which is configured to transitionbetween a neutral flexible state and a “jammed” state (i.e., asubstantially more rigid state as compared to the neutral flexiblestate). As such, at least one of the frame and seal portions can bemanipulated so as to change its shape and then the jamming enabledportion can be transitioned to a jammed state so as to retain the frameor seal portion in the adjusted shape.

Thus, in some embodiments, a respiratory mask includes a frame portionand a seal portion. The frame portion can include a perimeter and aconduit connector for connecting to a gas source. The perimeter can beconnected to the seal portion. The seal portion can include a sealingface configured to seal against the face of a patient. Additionally, atleast one of the frame portion and the seal portion can include avariable stiffness device configured to transition between a lowerstiffness state and a higher stiffness state, wherein the variablestiffness device included in the seal portion is configured to allow andretain an orientation of the sealing face of the seal portion.

In some embodiments, a customizable mask can include a conforming sealconfigured to utilize the physical process of granular jamming to enableit to adapt to a wide range of facial geometries. The mask can include aframe having a perimeter and a conduit connection, a conforming sealpositioned along the perimeter of the frame; the conforming seal mayinclude a sealing surface and a connecting surface, the connectingsurface configured to mate with the perimeter of the frame, and thesealing surface configured to conform to a users' face. The conformingseal can further include an outer casing, granular material containedwithin the outer casing, and a vacuum connection. The mask may alsoinclude a similarly configured conforming frame. Further disclosed aremethods of forming the mask.

Another aspect of at least one of the embodiments disclosed hereinincludes the realization that a clam shell-like behavior in a mask canbe desirable as it can allow such a mask to be customized to a widerrange of facial geometries. For example, a clam-shell configured maskcan be more easily varied to match both flat and wide facial geometries(such as Asian faces), and deep and narrow facial geometries (Europeanfaces). The profile of the mask seal conforms to the depth of the nasalbridge and other facial features and becomes narrower or wider inresponse to this conformance.

Another aspect of at least one of the embodiments disclosed hereinincludes the realization that other configurations can also be used toachieve one or more of the above-described benefits as well as otheroptional benefits. For example, in some embodiments, a mask can includea seal portion which combines a relatively stiffer, plasticallydeformable portion and an inflatable portion disposed between thestiffer portion and the patient. The inflatable portion can provideoptional additional benefits for improving seal performance.

In some configurations, a respiratory mask can be configured to fit aplurality of differently-shaped human faces. The mask can comprise aframe portion comprising a perimeter portion and a conduit connectionportion. A seal portion can be connected to the perimeter portion of theframe, the seal comprising a sealing surface and a connecting surface,the connecting surface being connected to the perimeter portion, thesealing surface configured to form a seal with a portion of a humanface. At least one of the frame portion and the seal portion cancomprise a variable stiffness portion configured to selectivelytransition between a decreased stiffness state and an increasedstiffness state.

In some configurations, wherein the frame portion is configured toextend over a respiratory orifice area of a plurality ofdifferently-shaped human faces.

In some configurations, the variable stiffness portion comprises adensity-dependent, variable viscosity material contained in acompressible chamber.

In some configurations, the variable viscosity material is a granularmaterial.

In some configurations, the compressible chamber is an air-tight bladderconfigured to maintain a vacuum therein and so as to collapse againstthe granular material, increase the density thereof and thereby increasethe viscosity of the granular material therein and transition thevariable stiffness portion to the increased stiffness state.

In some configurations, a releasable one-way valve can be mounted to theair-tight bladder.

In some configurations, the variable stiffness portion is included inthe seal portion and comprises an oblong cross section, a major axis ofthe oblong cross section extending along the width direction of the sealportion.

In some configurations, the variable stiffness portion is included inthe seal portion and comprises an oblong cross section, a major axis ofthe oblong cross section extending along the thickness direction of theseal portion.

In some configurations, the variable stiffness portion is included inthe seal portion, the variable stiffness portion defining at least about60% of the seal portion.

In some configurations, the variable stiffness portion is included inthe seal portion, and the variable stiffness portion extends across atleast about substantially the entire width of the seal portion.

In some configurations, the variable stiffness portion is included inthe seal portion and defines a layer of the seal portion.

In some configurations, the variable stiffness portion is included inthe seal portion and comprises a plurality of variable stiffness layers.

In some configurations, the plurality of variable stiffness layerscomprises at least first and second granular jamming chambers.

In some configurations, the first granular jamming chamber comprisesfirst granules and the second granular jamming chamber comprise secondgranules, the first granules being different from the second granules.

In some configurations, the first and second granular jamming chambersare fluidically connected.

In some configurations, the variable stiffness portion is disposed inthe seal portion between the perimeter portion of the frame and thesealing surface of the seal portion, the mask additionally comprising acushion portion disposed between the variable stiffness portion and thesealing surface.

In some configurations, the variable stiffness portion comprises agranular jamming chamber.

In some configurations, the cushion portion comprises a gel.

In some configurations, the cushion portion comprises a flap connectedto an outer surface of the seal portion and extending inwardly toward aninterior of the mask.

In some configurations, the cushion portion comprises a lip connected toan outer surface of the seal portion and extending inwardly toward aninterior of the mask.

In some configurations, the seal portion comprises at least onereinforcement strand extending along at least a portion of a length ofthe seal portion.

In some configurations, the at least one reinforcement strand extendsalong the entire length of the seal portion, forming a loop.

In some configurations, the frame comprises a seal support portionconnected to the seal portion and is configured to be deformable througha clam-shelling movement.

In some configurations, the frame comprises at least first and secondframe portions and at least a first flexible portion connecting thefirst and second frame portions and configured to allow the first andsecond frame portions to be moved relative to one another in theclam-shelling movement, wherein the first flexible portion comprises avariable stiffness portion, wherein the variable stiffness portion isconfigured to be selectively transitionable between a first moreflexible state and a second less flexible state, wherein the variablestiffness portion comprises a granular jamming chamber.

In some configurations, the first and second frame portions are stifferthan the seal portion and wherein the first and second frame portionsdefine at least a portion of the seal support portion.

In some configurations, the seal portion comprises an inflatable bladderdisposed between the sealing surface and the connecting surface.

In some embodiments, a respiratory mask can be configured to fit aplurality of differently-shaped human faces. The mask can comprise aseal portion comprising a sealing surface and a connecting surface, thesealing surface configured to form to a seal with a portion of a humanface disposed around a respiratory orifice of the human. A frame cancomprise a conduit connection portion and a seal support portionconnected to the connecting surface of the seal portion, the frameconfigured to be deformable through a clam-shelling movement.

In some configurations, the frame comprises at least a first and secondframe portions and at least a first flexible portion connecting thefirst and second frame portions and configured to allow the first andsecond frame portions to be moved relative to one another in theclam-shelling movement.

In some configurations, the first flexible portion comprises a variablestiffness portion.

In some configurations, the variable stiffness portion is configured tobe selectively transitionable between a first more flexible state and asecond less flexible state.

In some configurations, the variable stiffness portion comprises agranular jamming chamber.

In some configurations, the granular jamming portion comprises granularjamming material, the frame being configured to be foldable through theclam-shelling movement, between a folded configuration and an unfoldedconfiguration, the granular jamming material locking the frame in thefolded position when the variable stiffness portion is transitioned tothe second less flexible state.

In some configurations, the first and second frame portions are stifferthan the seal portion.

In some configurations, the first and second frame portions define atleast a portion of the seal support portion.

In some configurations, frame comprises a first hinge.

In some configurations, the first hinge extends across a central portionof the frame.

In some configurations, the first hinge comprises a fabric material.

In some configurations, the frame further comprises a second hinge.

In some configurations, the seal portion comprises a variable stiffnessseal portion.

In some configurations, the variable stiffness seal portion isconfigured to selectively transition between a decreased stiffness stateand an increased stiffness state.

In some configurations, the frame comprises first and second frameportions connected so as to be moveable relative to one another in theclam shelling movement, the variable stiffness seal portion beingconnected to both the first and second frame portions.

In some configurations, the first and second frame portions areconnected with a flexible frame portion, the variable stiffness sealportion extending across the flexible frame portion.

In some configurations, the first and second frame portions areconnected with a flexible frame portion, the variable stiffness sealportion extending across the flexible frame portion.

In some configurations, the frame is configured to be deformable into aplurality of different orientations through the clam shelling movement,the variable stiffness seal portion being configured to retain the framein the plurality of different orientations.

In some configurations, the seal portion comprises at least onereinforcement strand extending along at least a portion of a length ofthe seal portion.

In some configurations, the at least one reinforcement strand extendsalong the entire length of the seal portion, forming a loop.

In some embodiments, a respiratory mask can be configured to fit aplurality of differently-shaped human faces. The mask can comprise aframe portion comprising a perimeter portion and a conduit connectionportion. A seal portion connected to the perimeter portion of the frame,the seal comprising a sealing surface and a connecting surface, theconnecting surface being connected to the perimeter portion, the sealingsurface configured to form a seal with a portion of a human face, theseal portion comprising a layer of granular material and an inflatablebladder, the layer of granular material being disposed between the frameand the inflatable bladder.

In some configurations, the frame portion is configured to extend over arespiratory orifice area of a plurality of differently-shaped humanfaces.

In some configurations, the layer of granular material comprises adensity-dependent, variable viscosity material contained in acompressible chamber.

In some configurations, the compressible chamber is an air-tight bladderconfigured to maintain a vacuum therein and so as to collapse againstthe granular material, increase the density thereof and thereby increasethe viscosity of the granular material therein and transition thevariable stiffness portion to the increased stiffness state.

In some configurations, a releasable one-way valve can be mounted to theair-tight bladder.

In some embodiments, a respiratory mask can be configured to fit aplurality of differently-shaped human faces. The mask can comprise aframe portion comprising a perimeter portion and a conduit connectionportion. A seal portion can be connected to the perimeter portion of theframe, the seal comprising a sealing surface and a connecting surface,the connecting surface being connected to the perimeter portion, thesealing surface configured to form a seal with a portion of a humanface. At least one of the frame portion and the seal portion cancomprise a granular chamber comprising a plurality of granules.

In some configurations, the frame portion is configured to extend over arespiratory orifice area of a plurality of differently-shaped humanfaces.

In some configurations, the plurality of granules comprisedensity-dependent, variable viscosity material contained in the granularchamber which comprises a compressed chamber.

In some configurations, the granular chamber is an air-tight bladderwith an internal pressure below atmospheric pressure, squeezing walls ofthe granular chamber against the plurality of granules.

In some configurations, the granular chamber defines at least about 60%of the seal portion.

In some configurations, the granular chamber is included in the sealportion, and extends across at least about substantially the entirewidth of the seal portion.

In some configurations, the variable stiffness portion is included inthe seal portion and defines a layer of the seal portion.

The term “comprising” is used in the specification and claims, means“consisting at least in part of”. When interpreting a statement in thisspecification and claims that includes “comprising”, features other thanthat or those prefaced by the term may also be present. Related termssuch as “comprise” and “comprises” are to be interpreted in the samemanner.

In this specification where reference has been made to patentspecifications, other external documents, or other sources ofinformation, this is generally for the purpose of providing a contextfor discussing the features of the invention. Unless specifically statedotherwise, reference to such external documents is not to be construedas an admission that such documents, or such sources of information, inany jurisdiction, are prior art, or form part of the common generalknowledge in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 2 are schematic front elevational views of patient facesshowing injuries caused by known masks.

FIG. 2a is a perspective view of a mask secured to a patient's face andillustrating a leak of air flowing towards a patient's eye.

FIG. 2b is an enlarged side view of a portion of the seal of the mask ofFIG. 2a illustrating a point at which the leak occurs, identified by thearea 2 b of FIG. 2 a.

FIG. 2c is a sectional view of the portion of the seal illustrated inFIG. 2 b.

FIG. 3 is a schematic perspective and exploded view of a patient and amask in accordance with an embodiment.

FIG. 4a is a schematic front elevational view of an embodiment of themask of FIG. 3.

FIG. 4b is a partial side elevational and cross sectional view of themask of FIG. 4a applied to a user.

FIG. 4c is an enlarged schematic cross section view of a portion of themask illustrated in FIG. 4a taken along line 4 c-4 c.

FIGS. 5a and 5b are schematic cross-sectional diagrams taken along line5-5 of FIG. 4a , illustrating the mask applied to a face of a userhaving a flatter face and a user with a larger nose bridge and a moredeeply contoured face.

FIGS. 5c and 5d are schematic cross sectional views of a sealing portionof the masks of FIGS. 3-5, illustrating the adjustment of theorientation of the sealing surface of the seal portion.

FIGS. 6a, 6b and 6c are schematic views illustrating a variablestiffness device transitioning from a state of lower stiffness to higherstiffness.

FIG. 6d is a phase diagram relating jamming transition to inversedensity, stress and temperature.

FIGS. 7a-7d are schematic cross-sectional views of a mask illustratingthe process of adapting a mask to the shape of a particular user andtransitioning the variable stiffness device from a state of lowerstiffness to higher stiffness.

FIG. 8 is a schematic rear elevational view of the mask with differentconfigurations illustrated in phantom line.

FIG. 9 is a schematic side elevational and partial cross sectional viewof the mask in the three different orientations of FIG. 8.

FIGS. 10a and 10b are cross-sectional views of a further embodiment ofthe mask including support walls, FIG. 10a illustrating the mask in aneutral state and FIG. 10b illustrating the mask applied to a user'sface.

FIGS. 11a and 11b are cross-sectional views of yet another embodiment ofthe mask, FIG. 11a showing the mask in a neutral state and FIG. 11bshowing the mask applied to a user's face.

FIG. 12 is a side elevational and a partial sectional view of yetanother embodiment of the mask.

FIG. 13 is a side elevational and exploded view of the mask of FIG. 12and three optional conforming guides.

FIG. 14 is a schematic side elevational view of an embodiment ofheadgear that can be used in conjunction with any of the masks disclosedherein.

FIG. 15 is a partial cut-away view of a portion of the headgearillustrated in FIG. 14, and illustrating several optional layers thatcan be included in the headgear.

FIGS. 16a and 16b are schematic cross-sectional views of a furtherembodiment of the sealing portion of the mask including additionaloptional sealing membranes.

FIGS. 17a and 17b are cross-sectional views of a seal portion of a maskincluding an outer membrane before (FIG. 17a ) and after (FIG. 17b ) aforce is applied.

FIG. 18 is a cross-sectional view of another embodiment of the sealingportion of the mask with an optional additional sealing layer.

FIG. 19 is a cross-sectional view of another modification of the sealingportion of the mask, including an optional comfort layer.

FIG. 20 is a cross-sectional view of another modification of the sealportion of the mask including an optional soft sealing membrane.

FIG. 21 is a cross-sectional view of yet another embodiment of the sealportion of the mask including an optional soft sealing membrane.

FIG. 22a is a cross-sectional view of yet another modification of theseal portion of the mask including an internal skeleton member.

FIG. 22b is a partial cross-sectional and perspective view of yetanother modification of the seal portion of the mask, including internaltie members.

FIG. 22c is a cross-sectional and partial perspective view of anothermodification of the sealing portion of the mask, including an optionalplurality of structural layers within the seal portion.

FIG. 22d is a cross-sectional view of yet another modification of theseal portion of the mask, including structural beads in the sidewalls ofthe seal portion.

FIGS. 23 and 24 are side elevational and rear elevations views of themask illustrating a clam-shelling movement.

FIG. 24a is a schematic rear elevational view of another modification ofthe mask.

FIG. 24b is a schematic front elevational view of the mask of FIG. 24 a.

FIG. 24c is a schematic sectional view of the mask of FIG. 24aillustrating a reactionary movement of a seal of the mask of FIG. 24 a.

FIG. 25 is a schematic illustration of yet another modification of themask including layers of different granular materials.

FIG. 26a is a schematic sectional view of a modification of a sealportion including an inflatable bladder, in a deflated state.

FIG. 26b is a schematic sectional view of the seal of FIG. 26a in aninflated state.

FIG. 27a is a schematic sectional view of yet another modification ofthe seal, in a deflated state.

FIG. 27b is a schematic sectional view of the seal of FIG. 27a , in aninflated state.

FIG. 28a is a sectional view of yet another modification of the seal, ina deflated state.

FIG. 28b is a schematic sectional view of the seal of FIG. 28a , in aninflated state.

FIG. 29a is a schematic sectional view of yet another modification ofthe seal, in a deflated state.

FIG. 29b is a schematic sectional view of the seal of FIG. 29a , in aninflated state.

FIG. 30 is a schematic sectional view of yet another modification of themask including the seals of FIG. 26a , in a relaxed state.

FIG. 31 is a schematic sectional view of the mask of FIG. 30, in a statein which an outer surface of the seal is touching a surface of apatient.

FIG. 32 is a schematic sectional view of the mask of FIG. 30, in a statein which the seal is pressed against a surface of a patient such thatportions of the seal are deformed from the relaxed state of FIG. 30.

FIG. 33 is a sectional view of the mask of FIG. 30, illustrating atransition of a portion of the seal to a state of greater stiffness.

FIG. 34 is a schematic sectional view of the mask of FIG. 30, with aninflatable bladder shown in an inflated state.

FIG. 35 is a sectional view of the mask of FIG. 34, with the bladderreturned to a deflated state, and returned to a neutral state after thestate illustrated in FIG. 34.

FIG. 36 is an enlarged sectional view of the mask of FIG. 30,illustrating a contour of an outer surface of the seal during use.

FIGS. 37 and 38 are schematic views of a vacuum supply device, in twodifferent states.

FIG. 39 is a schematic illustration of a modification of the vacuumsupply device of FIGS. 37 and 38.

FIG. 40 is a schematic illustration of yet another modification of thevacuum supply device.

FIG. 41 is a flow chart illustrating a method that can be used forfitting a mask onto a patient.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The embodiments described below are described in the context oftherapeutic fluid delivery devices which include seals designed to formseals with areas of patients encircling a target treatment area.However, the inventions disclosed herein can be applied to other devicesdesigned for uses in other environments, including devices fornon-medical uses, and uses on non-humans, and/or inanimate objects.

FIG. 3 schematically illustrates an embodiment of a mask 100′ includinga variable stiffness portion which provides improved compatibility withdifferently-shaped contours of a user or patient. The mask 100′ includesa frame portion 102′, a seal portion 104′ and a conduit connection 106′.The frame portion 102′ is configured to extend over a target portion Rof a patient to be treated with the mask 100′. For example, but withoutlimitation, the target area R can be an area of the patient's body, suchas the patient's skin with an undesirable characteristic, such asdisease, an incision, a wound or at least one respiratory orifice of apatient, which can be, for example but without limitation, the nostrils,nose, and/or mouth of a patient. The conduit connection 106′ can be inthe form of a connection for receiving or discharging fluids or solids.For example, the conduit connection 106′ can be in the form of arespiratory conduit connection, which can optionally be incorporatedinto an aperture of the frame 102′ to provide connection to arespiratory air conduit. The air conduit 108′ can be of the type forsupplying a flow of pressurized breathable gases to the mask 100′.

The mask 100′, as noted above, can be configured for providing a sealingarrangement with respect to a target portion R of the patient's body,such as the skin, or one or any combination of a patient's respiratoryorifices, such as one or both nostrils (e.g., nasal masks), the mouth(oral masks), tracheotomy incisions, as well as other types of wounds,incisions, orifices, or areas to be treated with the mask 100′. As such,the seal 104′ can be configured to generate a seal with an area orportion of the patient AS surrounding any one or any combination of thetarget portions R noted above. The portion AS can be in the form ofskin, hair, with or without or other structures intended to be left inplace during use of the mask 100, such as a nasogastric tube.Additionally, in any of the above noted configurations, the mask 100′can also include one or any combination of the various featuresdisclosed herein, including granular jamming, clam shelling, and otherconcepts described in greater detail below. For example, but withoutlimitation, in embodiments where the mask 100′ is in the form of apillow-type nasal mask, the seal 104′ can be in the form of a bulbousmember configured to generate seals around the nares of a patient'snose. In such embodiments, the patient's nares corresponds to therespiratory orifice R of FIG. 3 and the skin tissue surrounding thepatient's nares corresponds to the area AS of FIG. 3. Known nasal-typemasks are commercially available in various forms, including the PilairoQ and Opus 360 masks available from Fisher & Paykel Healthcare.

In some embodiments, the mask 100′ can include at least one variablestiffness portion. Such a variable stiffness portion can be in the formof a granular jamming chamber configured to transition between differentstates of stiffness. For example, such a granular jamming chamber (notshown) can be incorporated into portions of the seal 104′ positioned ator proximate to the portions of the seal 104′ which contact the area AS.The use and transitioning of the granular jamming chamber of suchembodiments can be the same or similar to the descriptions set forthbelow with regard to granular jamming of the other embodiments of themask 100′.

FIGS. 4a, 4b, and 4c , illustrate a further embodiment of the mask 100′,identified by the reference numeral 100. Parts, components and featuresof the mask 100 which are similar or the same as corresponding parts orfeatures of the mask 100′ are identified by the same reference numeralexcept that the “′” has been omitted.

The mask 100 is configured to extend over and form a seal with the skinsurrounding a patient's nose and mouth. However, other configurationscan also be used. The frame 102 also includes a perimeter portion 110.The perimeter portion is configured for connection to the seal portion104.

The frame portion 102 can be substantially rigid. Thus, the seal portion104 provides more flexibility for following the contours of the user'sface so as to provide the desired seal during use. More particularly,the seal portion 104 is configured to form a substantially airtightconnection with both the perimeter portion 110 of the frame as well asthe skin surrounding the patient's nose and mouth. The connectionbetween the perimeter portion 110 of the frame 102 and the seal portion104 can be permanent or detachable.

In accordance with at least one of the embodiments disclosed herein, theseal portion 104 includes at least one variable stiffness portiontherein. For example, the seal portion 104 of the mask 100 can be formednearly entirely with materials or mechanisms that can be transitionedbetween different states of stiffness. In some embodiments, the entireseal portion 104 can be made from a single chamber and filled withparticulate or granular materials, liquids, solutions, non-newtonianfluids or other materials. In some embodiments, the materials used areof the type that can be used in conjunction with a technique known as“granular jamming” in which the material transitions from a state oflower stiffness or lower viscosity (e.g., flowable, flexible,conformable) to a state of increased stiffness or increased viscosity(stiffer, hardened, rigid). Such granules can be small or large, can becircular or polygon or could have random or varied shapes. However,other techniques and materials can also be used.

As used herein, the term “width of the sealing surface 122” is intendedto refer to the width measured in direction “W” as illustrated in FIG.4c . In some areas along the length “L” (FIG. 4a ) of the seal portion104, the width W of the sealing surface 122 can lie generally in the X-Yplane identified in FIG. 4c , for example, when the seal portion 104 isa neutral state. However, other portions of the sealing surface 122 canextend into the Z-axis and when the sealing portion 104 is adjusted orconformed to a user's face, the orientation of the sealing surface 122can be changed such that it extends along the Z-axis as well.

The term “thickness of the seal portion” is intended to refer to thedimension labeled as “T” in FIG. 4c . The thickness T of the sealportion 104 extends in the Z-dimension identified in FIG. 4 b.

The term “length of the seal portion” is intended to refer to the lengthL of the seal portion 104 as measured around the periphery of the mask100. The length L of the seal portion 104 does not normally extend onlyalong a single plane and thus would normally extend along a“3-Dimensional” path around the periphery 110 of the mask 100.

The sealing surface 122 or “face” of the sealing portion 104 is theportion of the sealing portion 104 that is most proximal to the face ofthe patient, in the Z-axis direction. Portions of the sealing face 122might approximately lie in the X-Y plane when in a neutral or relaxedstate. However, one of the benefits of the designs disclosed herein isthat the orientation of the sealing face 122, relative to the X-Y plane,can be adjusted and better stabilized in an adjusted shape with one ormore of the embodiments disclosed herein, described in greater detailbelow with reference to FIGS. 5c and 5 d.

Using these dimensional labels for reference, in some embodiments, theat least one variable stiffness portion of the seal portion 104 canextend along only a portion of the longitudinal length L of the sealportion 104 or along the entire length L of the seal portion 104.

Additionally, at least one variable stiffness portion of the sealportion 104 can include a part of the seal portion extending alongsubstantially the entire width W of the seal portion 104. As usedherein, the phrase “substantially an entire width of the seal portion”is intended to mean at least approximately 75% to 80% of the width W ofthe seal portion 104. Additionally, in some embodiments, at least onevariable stiffness portion of the seal portion 104 can be in the form ofone or more layers within the seal portion 104.

With continued reference to FIGS. 4a and 4 b, in some embodiments, theseal portion 104 includes an outer casing 112. The outer casing 112 canbe made from various different materials. In some embodiments, the outercasing 112 can form a variable stiffness chamber, for example, forming agranular jamming variable stiffness device of the mask 100. For example,the outer casing 112 can be in the form of an airtight chamber filledwith granular jamming material 114. As such, the outer casing 112 caninclude an actuation port 116 configured to allow air or gas or anotherfluid or liquid to be withdrawn from the interior of the outer casing112, to thereby increase the density of the granular jamming material114 and thus increase the stiffness of the seal portion 104.

For example, the mask 100 can further include a vacuum connectionconduit 118 and a valve 120 through which suction can be applied, forexample, to create a vacuum within the outer casing 112, to therebyreduce the fluid pressure within the outer casing 112 to a pressurebelow that of atmospheric, thereby allowing atmospheric air to squeezethe outer casing 112 and thereby increase the density of the granularjamming material 114 and thereby increase the stiffness of the sealportion 104. Optionally, the valve 120 can be in the form of a one-waycheck valve. Further, in some embodiments, the valve 120 can include arelease mechanism, for example, a button, for “releasing” the vacuum,i.e., allowing air to flow back into the outer casing 112. Othertechniques can also be used.

Optionally, in some embodiments, the frame 102 can include a moreflexible portion 109, for example, in the form of a hinge or otherdevice or connection that allows for deflection. As shown in FIG. 4a ,the hinge 109 can extend along a vertical centerline of the frame 102.Other configurations can also be used, for example, multiple hinges 109in various locations of the mask 100 can be used. Additionally, one ormore hinges 109 can be made from various materials and can be providedwith various optional functionalities. For example, one or more hinges109 can be made from fabric or other flexible materials. Optionally, oneor more hinges can be entirely or have one or more portions configuredto be provide variable stiffness, described below. As such, the frame102 can be more easily deflected or folded, at least partially, about anaxis that is approximately along the vertical centerline of the frame102. Such a flexible portion 109 can more easily accommodate aclam-shelling movement, described in greater detail below with referenceto FIGS. 23 and 24. FIG. 4a shows an optional configuration in which thelower end of the flexible portion 109 extends around one side of theconduit connection 106. Other orientations and configurations of theflexible portion 109 can also be used. For example, FIG. 4a illustratesan optional orientation of a flexible portion 111 as extending generallyhorizontally. Other orientations and configurations can also be used.

Additionally, the variable stiffness functionality of the seal portion104 described above can also function for securing or fixing therelative orientations of portions of the frame 102 disposed on oppositesides of the any of the flexible portions 109, 111. Additionally, asdescribed in greater detail below with reference to FIG. 12, the frame102 or the flexible portions 109, 111 can include or comprise variablestiffness devices and/or functionality, for example, in the form ofgranular jamming-enabled portions of the frame.

FIGS. 5a and 5b generally illustrate the concept of using a variablestiffness portion within the seal portion 104 to provide conformancewith different shapes of patient faces. More specifically, FIGS. 5a and5b generally correspond to the cross-section identified by the line 5-5in FIG. 4a , showing a partial cross section through an area of the sealportion 104 and mask frame 102 extending over a bridge of a user's noseand across and onto portions of the patient's cheek adjacent to the nosebridge. The cross-section of FIGS. 5a and 5b are intended to passthrough the sealing surface 122 between the seal portion 104 and skin ofthe user's face.

FIG. 5a illustrates the application of the mask 100 to a user having aflatter face with a shallower nose bridge which can also be referred toas a “flatter” facial geometry.

By contrast, FIG. 5b illustrates the application of the mask 100 to apatient having a much larger nose and more pointed face. By including atleast one variable stiffness portion in the mask 100, the mask 100 canbetter conform to such different facial geometries.

In some embodiments, in the process of conforming to the contours of auser's face, the sealing surface 122 can be moved from a neutral state(FIG. 5c ), in which in the illustrated example the sealing surface 122extends generally along the X-Y plane, to a conformed state in which thesealing surface 122 is distorted out of the X-Y plane. The variablestiffness portion of the sealing portion 104, can then be transitionedinto the jammed state, so as to preserve the adjusted/distortedorientation of the sealing surface 122 to better conform to a particularuser's facial contours. Similarly, adjustments and distortions in theX-Z plane can also be made and preserved. In some embodiments, suchenhanced conformability can be achieved by forming the entire sealportion 104 with a variable stiffness functionality, forming at leastabout 60%-80% of the seal portion 104 with a variable stiffnessfunctionality. The proportion of the variable stiffness portion to theoverall size of the seal 104 can depend on various factors including thetype of devices used to form the variable stiffness portion. Heregranular jamming is used, such factors can include the material usedwhether fluids or solids, the size of the particulates or granules, theshapes of those materials, the coefficient of friction between pieces ofthose materials, and other factors. In some embodiments, the seal 104can include at least one or more layers having variable stiffnessfunctionality. Optionally, the seal 104 can include a variable stiffnessportion that extends across at least about 75-80% of the width of thesealing surface 122, or with other structures, devices, orfunctionalities.

For example as noted above, the at least one variable stiffness portionof the mask 100 can operate on the principle known as “granular jamming”to better enable the mask to adapt to a wider range of facialgeometries. “Jamming” is a process where materials can have an initialfluid characteristic in a neutral state, in which the material can flow,move, or deform relatively freely, then pass through a transition phaseto become more rigid or stiffer, caused by an increase in density of thematerial. The transition of the material between a neutral and rigidstate can be referred to as the “jamming transition.”

The jamming transition can be described as a type of phase transition,with similarities to a glass transition but different from the formationof crystalline solids. For example, while a glass transition occurs whenthe liquid state is cooled, the jamming transition happens when thedensity of the material is increased. As the density of the materialincreases, the constituent particles, which can be in the form ofparticulates, granules or other materials which may or may not besuspended in a gaseous or liquid fluid, crowd together which preventsthem from exploring phase space, making the aggregate material becomestiffer, less flexible, less deformable and thus behave more as a solid.FIG. 6d includes a jamming phase diagram relating jamming transition toinverse density, stress and temperature.

The density at which systems jam is determined by many factors,including the shape of their components, the deformability of theparticles, frictional inter-particle forces, and the degree ofdispersity of the system. For example, a static sand pile can beconsidered as being “jammed” under the force of gravity while no energyis being dissipated. Systems which are consuming energy are alsosometimes described as being “jammed”. An example is traffic jams, wheredue to jamming the average velocity of cars on a road may drop sharply.Here the cars on a road may be thought of as like a granular material ora non-newtonian fluid that is being pumped through a tube. Under certainconditions, such as increased pressure causing increased density, theeffective viscosity of the non-newtonian fluid may rapidly increase,dramatically increasing the granular material or fluid's resistance toflowing and so causing the velocity to drop or even come to a completestop. In the traffic jam analogy, the cars are like the grains in agranular material and if they are dense enough (i.e., closely enoughspaced along the road) then interactions between the cars (as they mustavoid each other to avoid crashing) cause jamming. A simple model ofthis behavior is the Nagel-Schreckenberg model.

There are several factors that can contribute to when granular materialreaches a jammed phase or rigid state. These include but are not limitedto, the size and shape of the granules of the material. The jammingtransition can be induced by reducing the volume of fluid pressure ofthe volume within which the granular material is contained, therebyincreasing the density.

FIGS. 6a-6c are schematic views illustrating how a granular jammingprocess can occur. In all three FIGS. 6a, 6b, and 6c , a granularmaterial 132 including a fixed number of granules 134, are confinedwithin a container 130 along with a fluid 136, such as air or anothergas. In FIG. 6a , the container 130 forms a chamber with an initial or“neutral” volume that allows for relatively free movement of thegranules 134 of the granular material 132. Because there is some excessvolume within the container 130, the granules 134 are more free to move,in a fluid-like neutral state.

FIG. 6b illustrates a state in which some of the fluid 136 has beenremoved, for example, by application of a vacuum. The reduced volume ofthe chamber 130 forces the granules 134 into more contact with eachother such that they may begin to “jam” together as a result of thereduced shape or volume of the chamber 130 and frictional forces betweenthe granules 134.

With continued reference to FIG. 6b , with the reduced volume of thechamber 130, the granules 134 may achieve a semi-rigid state during thetransition into the jamming phase. With further removal of fluid 136from the chamber 130, the granules 134 can be pressed together into aneven greater density state until they achieve a rigid state orsignificantly increased viscosity.

FIG. 6c can be considered as illustrating a “jammed” state wherein thegranular material 132 is substantially rigid. Depending on thearrangement of the granules 134 when the volume of the chamber 130 isreduced, a nearly infinite array of different configurations ispossible. Further, with the use of some types of granules 134 and theuse of more flexible materials for forming the chamber 130, even in thestate illustrated in FIG. 6c , the chamber 130 can remain somewhatflexible or elastic. For example, the granules can be in the form oftalcum powder, sands, materials commercially available under the tradename Sands Alive!™, or other solids/granular material. Thus, dependingon the materials chosen, it can be possible to change the overall shapeof the chamber 134 when in a jammed state, by applying a force greatenough to overcome the frictional forces between the granules 134.

Using such a structure as schematically illustrated in FIGS. 6a -6 c,including a collapsible chamber 130 and granular material 132, in atleast a portion of a frame 102 or a seal portion 104 of a mask 100, themask 100 can be made to better conform to a variety of different facialgeometries of patients, such as human faces. Thus, the mask 100 can beapplied or pressed against a face of a user when in a neutral state,(the state illustrated in FIG. 6a . Pressing the mask as such against apatient's face, can deform the chamber 130, re-arrange the sealingsurface 122, as well as other corresponding flexible portions of a masksuch as the mask frame 102. With portions of the mask 100 deformed assuch, the chamber 130 can be collapsed so as to transition the granularmaterial 132 into a partially or fully jammed state. As such, the mask100 would then be in a deformed state having contours that more closelymatch the contours of the patient's face, however, the mask 100 would bein a more neutral state in that additional external forces are notnecessary to maintain the mask 100 in the deformed state. Rather, thevariable stiffness portion, which may operate under the principle ofgranular jamming described above, maintains the mask 100 in the deformedstate. With the mask 100 deformed as such, the mask can then be appliedto a user's face, for example, with typical head straps, to provide amore continuous and even pressured seal around one or more respiratoryorifices of a patient, i.e., the nose and/or mouth of a patient. As suchthe mask 100 can provide the following, or other, benefits:

-   -   Alleviation of pressure points by allowing mask retention forces        to be spread evenly over the mask, also the seal may be less        likely to collapse and allow the mask frame to bottom-out on the        user's face,    -   Reduced skin pressure and leaks during use,    -   Reduced occurrences of shear force being applied to the face,        since the seal is unlikely to deform in use,    -   Improved seal, as a result of the mask being less likely to        deform when the user moves or when an external force, such as        hose drag, is applied, and    -   Improved patient compliance.    -   Improved conformance to components such as nasogastric tubes.

The above-described jamming transition can be induced with any of theabove-described variable stiffness portions of the mask 100, such as theseal portion 104 or any other portion of the mask 100, by removing afluid such as air, or any other suitable fluid, from the spaces betweenthe granules 134 so as to reduce the internal volume of the associatedchamber 130. As such, the overall density of the granules 134 within thechamber 130 is increased. This can be achieved through the applicationof a negative pressure or vacuum to the chamber 130, or other maskelement.

As used herein, the term “negative pressure” shall mean any pressurebelow atmospheric pressure. “Positive pressure” is intended to mean anypressure above atmospheric pressure.

The chamber 130 can be made of any flexible and/or elastic material suchas, but not limited to, silicone rubber or thermoplastic elastomers,enabling it to conform readily to the facial geometry of a user andadditionally to reduce in volume when a negative pressure is applied.Forming the chamber 130 with a flexible elastic outer casing can helpsuch a variable stiffness portion or device achieve a more completejammed state because the material forming the chamber 130 can expand andcontract and conform to the surfaces of the granules 134 which itcontacts. This can provide the additional optional benefit of achievinga more rigid state that better maintains a conformed shape.Additionally, the granular material 132 within the chamber 130 canfreely move and conform to a user's facial geometry when in asubstantially fluid, neutral state. Thus, the selection of fine granularmaterial 132 can enable the conforming seal to more closely match thefacial geometry of a user.

In some embodiments, the chamber 130 can be formed of a flexible butinelastic or substantially inelastic material. Use of such a materialcan result in the chamber 130 reaching an even more rigid state when ina fully jammed condition, however, may form creases in the outer surfaceof the chamber 130.

With continued reference to FIGS. 6a -6 c, the granules 134 can berounded. Rounded granules can slide more freely past one another andresult in a less rigid seal when in a jammed state. When roundedgranules 134 are in a neutral (un-jammed) state they have greaterfreedom of movement which allows them to conform more readily to thefacial geometry of a user. Additionally, rounded granules 134 can alsoinduce a pinching (clamshell) movement in the sides of the seal.Clam-shell movements are described in greater detail below withreference to FIGS. 23 and 24.

In some embodiments, the granules 134 forming the granular material 132can have different hardnesses. Optionally, the granules can havedifferent hardnesses in different regions of the seal portion 104.

Some of the granules 134 can comprise a soft and compressible materialthat is capable of undergoing elastic deformation. In some embodiments,sections of the seal portion 104 can have granules 134 with more elasticproperties which can provide additional benefits. Optionally, all of thegranules 134 can be soft or can comprise a mix of harder and softergranules. Although the softer granules included in the granules 134generate greater resistance against sliding and flowing over one anotherin the jammed state, they can individually and collectively deformelastically, and thereby partially and elastically absorb some movementsof a user's face, such as when the user moves their jaw, and betterminimize leaks during and after such movements, elastically returning tothe original shaped determined by the jamming process. Additionally,when under vacuum pressure, the softer granules 134 can conform to thegeometry of the users face, but not as closely as the incompressiblegranular material.

For example, when some configurations of a seal portion 104 includingonly harder incompressible granules have been shaped to a user's faceand subject to a vacuum to transition completely or partially to ajammed state, necking can occur in the seal portion 104 when the sealportion 104 is deformed, for example, when a user moves their jaw. Thenecking can result from the movement by the user (moving their jaw)overcoming the friction between the granules 134 and forcing some of thegranules 134 to move from their conformed position to a differentposition, thereby changing the shape and/or configuration of the sealingsurface 122. Such necking can occur due to tension on the seal 104 (forexample, in the direction of the length L identified in FIG. 4a ) as thepatient moves their jaw. This can happen during fitting or otherconditions when there is a tension. This necking can also occur inshear, e.g. while fitting with the skin, there can be a shear forceintroduced with the skin and cushion. As such, the conformed shape ofthe sealing surface 122 can be compromised because the harder granules134 can inhibit or reduce the ability of the seal 104 to return to thepre-necking shape.

By contrast, using at least some softer granules 134 or includingregions with at least some softer granules 134 in the seal portion 104,such forces (e.g., caused by movement of a user's jaw) can result insome necking in these regions and the granules 134 at least partiallystretching elastically and thus better able to return entirely orsubstantially to the previously conformed shape, after the user stopsmoving their jaw. This allows the user to move their jaw (such as duringyawning) whilst wearing the mask, without their movement beingrestricted and the seal being compromised. In some embodiments, theincompressible material and the compressible material can be separatedwithin the seal so that they do not intermingle. In some embodiments,the different regions of differing granule hardnesses can be separatedinto layers. Additionally, the different regions can be separated intosegments extending longitudinally along the seal portion.

FIGS. 7a, 7b, 7c and 7d are a series of figures illustrating a methodwhich can be used to conform a mask 100 to a patient's face, undervarying conditions. Firstly, FIG. 7a shows the mask 100 in a neutralstate as it could be prior to application to a user's face. At thispoint, the chamber 130 has a thickness T₁.

FIG. 7b shows the mask 100 having been pressed against a user's face,thereby deforming the chamber 130 so as to have a reduced thickness T₂.Because the chamber 130 and the granular material therein are in aneutral state, the compression of the chamber 130 as illustrated in FIG.7b does not apply a substantially greater force against the user's faceat the apex 140 of the illustrated contour of the patient's face, thepoint at which the thickness of the chamber 130 has been reduced tothickness T₂.

FIG. 7c illustrates a state of the mask 100 after a vacuum has beenapplied to the chamber 130. More specifically, a vacuum had been appliedto the chamber 130 so as to remove excess air from within the chamber130, thus causing the granular material 132 within the chamber 130 toachieve a jammed state.

FIG. 7d illustrates how the chamber 130 maintains the deformed shapeachieved during the jamming state described above with reference to FIG.7c , even after having been removed from the user's face. Thus,generally, a method for conforming the seal portion 104 of the mask 100to a patient's face can include the following steps:

-   -   1. Appling the mask 100 to a user's face, with the mask 100 in a        neutral state.    -   2. Conforming the granular material within the chamber 130 and        the mask to a user's facial geometry, while in a neutral state.    -   3. Applying a negative pressure to the chamber 130, thus        reducing the volume of the chamber 130 and increasing the        density of the granular material 132 within the chamber 130. As        such, the vacuum causes the chamber 130 to shrink and thus        causes the seal portion 104 to shrink onto the user's face, with        the chamber 130 becoming substantially rigid and retaining the        shape of the user's face.

In some embodiments, a mask constructed as such can include a mechanismfor releasing the vacuum, i.e., allowing atmospheric air to flow backinto the chamber 130, thereby allowing the chamber 130 to return to aneutral state. Thus, a mask 100 that includes such a feature can bereconfigured many times to suit different users or different situations.The granular jamming process, in other words, can be reversed to allowthe mask 100 to transition from the jammed state back to a neutralstate, in which the mask is again flexible. The reversal of the jammingprocess can be achieved by releasing the applied vacuum and allowing thepressure within the chamber 130 to return to a level at which thegranular material achieves a neutral state, or by providing a positiveflow of air into the chamber 130 to speed the process of transitioningback to the neutral state.

With reference to FIGS. 8 and 9, in embodiments where seal portion 104forms the chamber 130 and is made from an elastic material, the sealportion 104 can be enlarged and contracted in such a way such that thesealing surface 122 of the seal portion 104 can be made larger orsmaller, for example, in a plurality of different sizes that can bedescribed as concentric relative to one another. For example, as shownin FIGS. 8 and 9, the seal portion 104 can be designed to remain in aneutral state in the shape identified with the letter M, correspondingto a “medium” size. Thus, where the outer casing 112, which in thisembodiment, can form the chamber 130, is made from an elastic material,the seal portion 104 can be enlarged into the shape identified by theletter L corresponding to a “large” size. Similarly, the seal portion104 can be contracted into a smaller shape, corresponding to the shapeidentified as S corresponding to a “small” size. As such, the sealingsurface 122 changes size and shape, illustrated as 122L for the largesize, 122M for the medium size, and 122S for the small size.

Enlarged or contracted as such, and applied to a user's face, a vacuumcan be applied to the chamber 130, thereby transitioning the chamber toa jammed state such that seal portion 104 can maintain the shapecorresponding to one of the three sizes illustrated small, medium,large, or any size there between.

The ability to modify the size of the mask 100 can also be used toprovide different sealing arrangements. For example, in full-face maskembodiments, where the seal portion 104 is configured to fit around auser's nose and mouth, it may be beneficial to be able to change thearrangement of the seal portion 104 to sit above or below the chin ofthe user. This can improve user comfort and compliance.

FIGS. 10a and 10b illustrate a modification of the mask 100 and isidentified generally by the reference numeral 200. Parts, components andfeatures of the mask 200 which are similar or the same as correspondingparts or features of the mask 100 are identified by the same referencenumeral except that a value of 100 has been added thereto.

With reference to FIG. 10a , the mask 200 can include a modified frame202, and in particular, a modified perimeter 210 relative to theperimeter 110 of the mask 100. More specifically, the perimeter portion210 of the mask 200 includes outer support wall 240 and inner supportwall 242. The outer and inner support walls 240, 242 can extend aroundthe entirety or only a portion of the perimeter 210 of the frame 202.The outer and inner support walls 240, 242 can be made from the samematerial as the frame 202. Additionally, the outer and inner supportwalls 240, 242 can extend generally parallel to one another and thusform a channel around the perimeter 210 of the frame 202. Disposedbetween the outer and inner support walls 240, 242, the frame caninclude a connecting surface 244.

The connecting surface 244 can be used with or without the inwardlyfacing surfaces of the outer support wall and inner support wall 240,242 to form a connection to the seal portion 204. In the illustratedconfiguration, the outer and inner support walls 240, 242 extendgenerally along the thickness T of the seal portion 204. As such, theouter and inner support walls 240, 242 can aid in providing anadditional optional benefit of limiting the deformation of the sealportion 204 when the seal portion 204 is in a neutral conforming state.

For example, the outer and inner support walls 240, 242 can reduce oreliminate the likelihood that the seal portion can become completely“bottomed out” or in other words deformed to the point where thethickness T could be reduced to zero or near zero, with virtually littleor no granular material 232 between the sealing surface 222 and theconnecting surface 244. If such a bottoming out occurs, the stiffness ofthe associated portion of the seal portion 204 would not besignificantly raised by the jamming process. This is because without thegranular material located in such a pinched portion of the seal portion204, the frictional forces between the granules 234 would not be presentto provide the stiffening associated with a granular jamming principleof operation.

Additionally, the outer and inner support walls 240, 242 can helpconcentrate the “z axis” deformation of the seal portion 204. In otherwords, the outer and inner walls 240, 242 can resist the widening of theseal portion 204 disposed between the outer and inner walls 240, 242thereby concentrating more of the expansion of the seal portion 204 andthus the width W of the sealing surface 222, as illustrated in FIG. 10b. As such, the portion of the sealing surface 222 in contact with theskin of the user grows, thereby creating a larger contact patch betweenthe seal portion 204 and the skin of the user. FIGS. 10a and 10b alsoillustrate how the sealing surface 222 in the neutral state (FIG. 10a )is re-shaped and oriented to follow a curved shape along an arc (FIG.10b ) that is distorted out of the X-Y plane, into the Z-axis.Additionally, FIGS. 10a and 10b illustrate that the sealing surface 222,when in a neural state (FIG. 10a ) can have a convex shape and when in aconformed and jammed state (FIG. 10b ) can have a concave shape, therebyproviding enhanced conformability.

Further, along the lines discussed above with the manner in which theseal portion 204 enlarged as noted above with regard to FIG. 10b , theenlargement of the sealing surface 222 and the other surrounding portionof the seal portion 204 proximal to the user's face can also helpprevent any part of the frame 202 from contacting the user's face andcausing associated discomfort.

With continued reference to FIGS. 10a and 10b , the outer and innersupport walls 240, 242 can be configured to be a semi-rigid orsubstantially rigid extension of the frame 202. For example, theconnecting surface of the seal portion 204 is disposed between the outerand inner walls 240, 242 and thus can act as a retention for the sealportion 204.

FIG. 10b shows the seal portion 204 being deformed from a neutral state,as being pressed against a user's face. As such, the deformationgenerally occurs outside of the support walls 240, 242. During a jammingtransition, the seal portion 204 can shrink while maintaining asubstantially similar geometry to that shown in FIG. 10 b.

FIGS. 11a and 11b illustrate a modification of the mask 200 which isidentified generally by the reference numeral 300. Parts, components,and features of the mask 300 that are similar or the same ascorresponding parts, components, or features of the mask 200 areidentified with the same reference numerals, except that a value of 100has been added to the reference numerals used to identify correspondingparts of the mask 200.

As shown in FIGS. 11a and 11 b, the mask 300 can include outer and innersupport walls 340, 342 which are made integral with the material formingthe outer casing 312, which as in the previous embodiments, also formsthe chamber 330.

As described above with reference to the outer casing 112 and 212, theouter casing 312 can be made from a flexible and/or elastic material. Inthe illustrated embodiment, the outer casing 312 includes a thickenedarea 350 which is generally in the shape of a channel portion includingthe outer and inner support walls 340, 342. Although the thickenedportion 350 is made from a flexible material, such as silicone, rubberor other materials, the additional thickness relative to the otherportions of the outer casing 112 provides the thickened region with adifferent and greater stiffness. In other words, the thickened region350 can have a higher spring constant than the other portions of theouter casing 312. In other words, more force is required to deform thethickened region, than the remaining parts of the outer casing 312. Assuch, the deformation of the seal portion 304 can be similar to thedeformation of the seal portion 204 described above with reference toFIGS. 10a and 10 b.

Additionally, forming the outer and inner support walls 340, 342integrally with the outer casing 312 can provide the additional benefitof a smoother, softer transition between the more flexible portion ofthe outer casing 312 and the thickened region 350, thereby furtherpreventing user discomfort.

Optionally, the thickened region 350, including the outer and innersupport walls 340, 342 can gradually taper into thinner supple regionsof the outer casing 312.

As shown in FIG. 11 b, when the seal portion 204 is deformed against theuser's face, the support walls 340, 342 can at least partially splayapart as the seal portion 304 is compressed. Such a structure canprovide for a more controlled deformation of the seal portion 304. Thetapered thicknesses of the support walls 340, 342 can better controlwhere and how deformation occurs, for example, allowing greaterdeformation of the seal portion 204 in regions proximal to the user'sface as compared to the regions proximal to the frame 302.

In some embodiments of any of the masks 100, 200, 300, and the othermasks described below, any of the masks can be constructed with only aportion of the seal 304 having a variable stiffness, such as through theuse of granular jamming ability. For example, the granular jammingability of the seal portion 304 can be limited to regions of the mask300 that are proximate to those portions a user's face which aretypically more challenging for achieving an airtight seal, for example,in the area around the bridge of the nose and the transitions to theadjacent cheek areas.

Additionally, variable stiffness functionality can also be used in areasthat are susceptible to pressure related skin damage resulting fromexcessive application forces, for example, as discussed above withreference to FIGS. 1 and 2. The variable stiffness abilities, includingthe granular jamming principle of operation described above, can be moreeffective at deforming to match complicated geometries in an around thenose bridge, thus reducing leaks and dispersing application forces moreevenly. Traditional seal designs can be used in other regions of themask. Such a mask can help reduce the weight of the mask because thecomponents necessary for providing the granular jamming functionalitycan weigh more than conventional mask components.

FIG. 12 illustrates yet another modification of the mask 100, and isgenerally identified by the reference numeral 400. Parts, components,and features of the mask 400 which are similar or the same to any of theabove-described masks are identified with the same reference numerals,except that a value of 100 has been added to the reference numerals usedfor describing the mask 300. In the illustrated embodiment, the mask 400includes a frame 402, at least a portion of which (e.g., flexibleregions) includes a structure configured for providing variablestiffness, for example, operating in accordance with the granularjamming principle of operation. The flexible regions allow for threedimensional deformation of the mask frame. In some embodiments thegeometry of the flexible region may bias deformation to certaindirections. In some embodiments, some portions of the frame 402 compriseflexible regions and other parts of the frame 402 substantially rigidportions. In other words, the frame can comprise one or more less rigidportions and one or more, more rigid portions. For example, as describedabove with reference to FIGS. 4a -4 c, the frame 402 can comprise one ormore flexible portions 109, 111 (FIG. 4a ), which can serve as hingesand, optionally, can be in the form of granular jamming-enabled portionsof the frame 402.

In some embodiments, such flexible portions can be in the form ofpockets, for example, made with elastic material and filled withgranular jamming materials 432. Additionally, the pocket can include avacuum connection so that the pocket can be transitioned to a jammedstate. In some embodiments, the flexible pockets can be formed with theframe by over-molding, however, other techniques can also be used.Additionally, in some embodiments, the flexible pockets can be made fromdifferent materials than the more rigid portions of the frame 402.

For example, one or more portions of or the entire the frame 402 caninclude one a substantially flexible and/or elastic frame casing 456,configured to contain a granular material 432. As such, the casing 456forms a granular jamming chamber. Additionally, the mask 400 can includean additional vacuum connection 458 configured to allow the applicationof a vacuum to the interior of the chamber 456 for moving fluid from thechamber 456 and achieving a transition from neutral to jammed states, inthe manner described above with reference to the seal portion. A conduitconnection 408 can extend through the chamber 456 for providing apassage for breathable and optionally pressurized gasses.

Additionally, although not shown, the vacuum connection 458 can alsoinclude a one-way valve for maintaining a vacuum applied to the chamber456, so as to maintain the chamber 456 in a conformed jammed state.

Similarly, the seal portion 404 can be made entirely of a granularjamming chamber, can include only a portion in the form of a granularjamming chamber, or can be made entirely out of a conventional sealingarrangement without any granular jamming.

With regard to the frame 402, the chamber 456, being made from aflexible and/or elastic material, can be configured to contain thegranular material 432 which is also used within the seal portion 404.However, the chambers 430 and 456 can use different granular materials432. The chamber 456 and the seal portion 404, in embodiments where bothinclude at least a portion having a variable stiffness functionality,can be configured to adapt to a user's face in a similar manner as theseal portions described above of the previously described embodiments.For example, granular jamming can be utilized to shape the chamber 456and/or the seal portion 404 to more closely match a user's facialgeometry than traditional masks. For example, in some embodiments ofmethods of use thereof, the following steps can be employed:

-   -   1. Apply the frame 402, which includes the chamber 456, to a        user's face while in a neutral state, and with the seal portion        404 detached.    -   2. Allow the granular material 432 in the chamber 456 to conform        to the user's facial geometry, while in a neutral state.    -   3. Apply a vacuum to the chamber 456, for example, through the        vacuum connection 458, to thereby increase the density of the        granular material 432 in the chamber 456. The vacuum can cause        the chamber 456 to shrink onto the user's face, for example,        becoming an effective rigid casting of the user's face.    -   4. Remove the frame 402 from the user's face with it in a jammed        state.    -   5. Attach the seal portion 404 to the frame 402, with the seal        portion 404 in a neutral state and the frame 402 in a jammed        state.    -   6. Apply the assembled mask 400 to the user's face, allowing the        granular material 432 in the seal portion 404 to conform to the        user's facial geometry.    -   7. Apply a vacuum to the seal portion 404 via the vacuum        connection 416 thereby reducing the volume of the chamber 430,        causing the chamber 430 to shrink onto the user's face, and        becoming a substantially rigid casting of the user's face.

In the method set forth above, the customization of the mask 400 can beconducted in a two phase process, first customizing the shape of theframe 402, then customizing the shape of the seal portion 404. As such,the mask frame 402 itself can better follow the contours of thepatient's face and thus require less deformation of the seal portion 404thus better reducing dead-space and the associated rebreathing of airwithin the mask. The seal portion 404 acts as a spacer between the frame402 and the user's face. Having a small amount of space between theframe 402 and the user's face may allow for the user to move their faceor change position more easily than if the frame 402 were positionedcloser or even in direct contact with the user's face, thus improvingcomfort and compliance.

With reference to FIG. 13, optionally, the mask 400 can benefit from theuse of templates or forming guides to assist in the process ofconforming the frame 402 to a user's face. For example, in somenon-limiting embodiments, as shown in FIG. 13, small, medium and largeconforming guides 460, 462, 464 can be in the form of substantiallyrigid shells designed to approximate three different sizes of facialgeometries of a range of users. The sizes of the forming guides 460,462, 464 can be predetermined to fit a range of facial geometry shapesand sizes. For example, the forming guides 460, 462, 464 may beavailable in small, medium, and large sizes and/or variants that caterfor wide, narrow, or normal width faces. Other embodiments of theconforming guides 460, 462, 464 can cater to flatter or more pronouncedfacial profiles.

In a method of use, one of the conforming guides 460, 462, 464 can bechosen based on which is the best match for the geometry of a particularpatient's face. The chosen conforming guide can thus be used to mold andshape the frame 402, for example, when the chamber 456 is in a neutralstate. For example, the frame 402, with the chamber 456 in a neutralstate, can be placed over and shaped to match the chosen of the threeconforming guides 460, 462, 464. With the frame 402 applied to thechosen conforming guide as such, a vacuum can then be applied to theframe vacuum connection 468 to thereby shrink the chamber 456 andincrease the stiffness of the frame 402, for example, by subjecting thechamber 456 to a sufficient vacuum so as to transition the chamber 456into a jammed state. After such transition, the frame 402 can then becombined with the seal portion 404 and the above-described method ofconforming the mask 400 to a user's face can continue as describedabove.

The advantage of using a conforming guide, such as one of the conformingguides 460, 462, 464 is that a conforming guide can be made frommaterials that are substantially more rigid than a patient's face. Thus,when a vacuum is applied to the chamber 456, and shrinks to some degree,the frame 402 can be pressed with a greater force against the conformingguide so as to retain the desired shape, a process that might beuncomfortable for a patient. Additionally, in some embodiments whereonly a portion of the seal and/or frame includes the granular jammingfunctionality, the shrinking and associated compressive force may bebeneficial in increasing the sealing forces between the mask and theuser's face. This may improve the ability of the mask to form asubstantially airtight seal with the user's face.

In additional variations of the mask 400, a frame 402 can be used incombination with a traditional, non-variable stiffness seal portion.Such a traditional seal can comprise a silicone cushion as is commonlyused presently in the mask arts, or any suitable alternative, whereinthe seal is flexible but less conformable than the previously describedgranular jamming enabled seals.

With reference to FIG. 14, variable stiffness, for example by way of thegranular jamming principle of operation, can optionally be incorporatedinto a headgear arrangement for retaining a mask, such as any of themasks 100, 200, 300, 400 described above, or any of the masks describedbelow.

For example, FIG. 14 illustrates a non-limiting exemplary embodiment ofa headgear arrangement for the mask 100. The headgear 1000 can include acrown strap 1002, a rear portion 1004, an upper strap 1006, a lowerstrap 1008, an upper connection 1010 and a lower connection 1012. Theupper and lower connections 1010, 1012 can be configured to connect themask 100 to the headgear 1000.

Utilizing the process of granular jamming, the headgear 1000 can beconfigured to conform to a user's head shape and size, with reducedmanual adjustments. For example, airtight chambers and granular materialcan be incorporated into portions of the headgear 1000 so as to providea granular jamming functionality. For example, with reference to FIG.15, one or more portions of the headgear 1000 can include a granularjamming layer 1020. The granular layer 1020 can include a granular layercasing 1022 containing granular material 1024. The granular casing 1022can be made from a flexible and/or elastic material and can include avacuum connection and optionally a one-way valve (not shown). As such,the headgear 1000 can be applied to a user's head, and then a vacuum canbe applied to the chamber 1022 to thereby compress the granular material1024 and transition the granular layer 1020 into a jammed state.

A process of using such a headgear 1000 can include applying theheadgear 1000 to the head of a user with the granular layer chamber 1022in a neutral state. The headgear can be conformed to the user's headmanually, by pressing the headgear 1000 against the user's head. Then,with the headgear 1000 maintained to the conformed shape, a vacuum canbe applied to the chamber 1022 to thereby transition the layer 1020 intoa jammed state. As such, the granular layer 1020 can act as a sizingadjustment mechanism.

Optionally, the headgear 1000 can also include a shape sustaining layer1026. The shape sustaining layer 1026 can be made from a semi-rigidmaterial such that it can provide some structural support to theheadgear 1000 when the granular layer 1020 is in a flexible neutralstate. The shape sustaining layer 1026 may minimize the likelihood ofthe headgear tangling when it is not applied to a user's head, bykeeping the headgear in a substantially open, three-dimensional shape.It can be advantageous for the headgear 1000 to maintain a substantiallyopen three-dimensional shape as it can help fitting the headgear andmask more quickly and more easily.

In some embodiments, the shape sustaining layer may only be included inone or limited parts of the headgear 1000 which benefit from additionalstructural support. Additionally, including a discontinuous shapesustaining layer throughout the headgear 1000 may allow for the headgearto conform more readily to the size and shape of different user's heads.

Further, the headgear 1000 can also include a cushioning layer 1028positioned on the inner side of the granular layer and/or the shapesustaining layer 1026 so as to provide additional comfort for the user.The cushioning layer 1028 can be configured to be in direct contact withthe user's head or skin or hair or may be separated from the user's headby a decorative outer layer. The cushioning layer 1028 can be made fromany soft material such as, but not limited to, foams, textiles,elastomers, and spacer fabrics. The cushioning layer 1028 can providecomfort to the user by softening any hard or sharp edges that may beformed by other layers within the headgear 1000. In some embodimentsthis layer 1028 may be elastic. Providing some elasticity in any of thelayers of the headgear can provide an additional benefit of a temporarypre-loading feature during fixation of the mask 100 on a patients face.After fitting, the transition to a jammed state reduces or eliminateselastic tension in the headgear, and the jammed state can help lock themask 100 on a patient's face. In the jammed state, the headgear 1000holds the mask 100 on the patient and resists blow-off forces that couldotherwise tend to push the mask away from the patient's face, forexample, when pressurized air is applied. As such, the headgear 1000 canremain more stationary.

Additionally, as noted above, the headgear 1000 can include a decorativeouter layer 1030 which can comprise a soft aesthetically pleasingsleeve, configured to cover any functional granularity of the shape ofthe granular layer 1020. In some embodiments, the decorative outer layermay encase the cushioning layer 1028 as well, or the cushioning layermay form the face contacting portion of the decorative outer layer. Thedecorative outer layer 1030 can be made from any suitable textile,polymer or other suitable material that is capable of providing acomfortable interface with the user's skin.

In some embodiments, the layered configuration of the headgear 1000illustrated in FIG. 15 can be applied to a headgear of any form, knownin the art, which differs from the form shown in FIG. 15. In someexamples, the headgear 1000 can comprise a single strap that extendsfrom one side of a user's face to the other, wherein the strap may bebifurcated at the rear of the user's head.

FIGS. 16a and 16b illustrate another modification of the seal portion404 of the mask 100, and is identified generally by the referencenumeral 504. Parts, components, and features of the seal portion 504that are the same or similar to those of the seal portion 404 have beenidentified with the same reference numerals except that a value of 100has been added thereto.

The seal portion 504 can be used in conjunction with any of the frameportions and masks described above and below. With continued referenceto FIG. 16a , the seal portion 504 includes an additional sealingmembrane that extends from an outer side of the seal portion 504, to aninner side of the seal portion 504. In the illustrated embodiment, thesealing membrane 570 includes a first connection end 572 connected tothe outer side of the outer casing 512 of the seal portion 504 andextends around the lower end of the seal portion 504 to a free end 574.As such, in cross-section, the sealing membrane 570 forms a “C” shape.The free end 574, can be in the form of a flap that extends from theseal portion 504, and is an extra portion of the seal portion 504 thatextends outwardly from the seal portion 504.

Optionally, as with some of the embodiments described above, the sealportion 504 can include a frame connection portion 544 configured forproviding a removable connection to an associated frame (not shown). Thesealing membrane 570 can comprise a thin flexible layer of material,such as, but not limited to, silicone rubber or a thermoplasticelastomer. Additionally, the sealing membrane 570 is configured toprovide a sealing surface with the skin of a user's face.

The membrane connection 572 attaches the sealing membrane 570 to theseal portion 504 and/or frame of the associated mask (not shown). Thesealing surface 576 of the sealing membrane 570 is configured to sitbetween the seal portion 504, and specifically, the outer casing 512which can include a chamber 530 which includes a granular material 532.The sealing surface 576 is configured to sit between the seal portion504 and the user's face to facilitate a substantially airtight sealbetween the seal portion 504 and the user's face. The sealing membrane570 can be configured to extend from the membrane connection 572, aroundthe outside of the seal portion 504 and between the user's face and theseal portion 504, terminating on the inside of the mask seal. In theembodiment of FIG. 16a , the sealing membrane 570 has a substantially“C” shaped cross-section, however, other cross-sections are alsopossible.

With reference to FIG. 16b , the seal portion 504 includes an integralsealing membrane 570 a. The sealing membrane 570 a can be configured asa thin flexible lip that extends from the sealing surface 576 of thesealing portion 504 towards the inside of the seal portion 504. Theinternal air pressure within the associated mask, during use, can causethe sealing membrane 570, 570 a to be pushed against the user's face andthereby enhance a seal there between. Optionally, the free end 574 andthe lip 570 a can made from a more resilient material and/or can bebiased into a shape extending away from the frame 502 and towards thepatient so as to enhance sealing with the patient's face.

FIGS. 17a and 17b illustrate yet another modification of the sealportion 504 and is identified generally by the reference numeral 604.Parts, components, and features of the seal portion 604 that are thesame or similar to the seal portion 504 have been identified with thesame reference numerals, except that a value of 100 has been addedthereto.

In the illustrated embodiment, the seal portion 604, which can beapplied to any of the masks and associated frames described above,includes a sealing membrane 670 which is offset from an outer casing 612of the seal portion 604. For example, an offset between the innersurface of the sealing membrane 670 and the outer surface of the outercasing 612 can be filled with a fluid, such as a gas or a liquid,including lubricants, air, oil, gel, powder, or water to provide areduced coefficient of friction between the inner surface of the sealingmembrane 670 and the outer surface of the outer casing 612. In someembodiments, such fluid can also serve as a comfort layer. In FIG. 17a ,the offset is identified generally by the reference numeral 680. Thus,with the chamber 630, in use, maintained in a “jammed” state, thesealing membrane can remain in a fixed stationary contact with theuser's face while allowing the chamber 630 to make some movements and/ordeformations.

For example, shear forces can be generated during use of the sealportions 604 and associated mask. Such shear forces can cause discomfortand skin damage to a user's face. For example, FIG. 17a illustrates theseal portion 604 in contact with a user's face, before any substantialforces are applied to it. The sealing membrane 670 and the chamber 630define a membrane contact point 681 and a seal contact point 682. Whenthe seal portion 604 is in a non-conformed state, the contact points canbe aligned with a face contact point 683.

FIG. 17b illustrates the seal portion 604 with a force F applied to it.As shown in FIG. 17b , the application of the force F causes the sealportion 604 to deform. As a result, the seal portion can movesubstantially independently of the sealing membrane 670, which is shownvia the movement of the seal contact point 682 relative to the membranecontact point 681 and the face contact point 683. This movement ispossible due to a higher friction force between the user's face and thesealing membrane 670 than there is between the sealing membrane 670 andthe outer surface of the chamber 630.

Optionally, in some embodiments, as shown in FIG. 18, the outer casing612 of the chamber 630 can include an additional sealing layer 684configured to form a sealing surface 685. The sealing layer 684 can bemade from a soft and compressible material, such as but not limited to,a polymer foam or a textile. The sealing layer 684 can be configured tobe softer and/or more compliant than the granular material within thechamber 630 when in a jammed state, thus allowing the sealing layer 684to fill any gaps that may exist between the outer surface of the chamber630 and the user's face.

With reference to FIG. 19, a further variation of the seal portion 604which includes a variation of the seal membrane 670. In this variationof the seal portion 604, the seal membrane 686 includes a taperingthickness. In other words, the seal membrane 686 includes a thickenedportion 687 in the vicinity of the skin contacting region 683 andthinner region 688 extending upwardly along the inner and outer sidewalls of the seal membrane 686. In the illustrated embodiment, the sealmembrane 686 can be made from a very soft and flexible material, such assilicone. Preferably, the material used to form the seal membrane 686can have a shore hardness in the lower half of the shore 00 scale. Amaterial of this softness can allow the thick region of the sealmembrane 687 to form a cushioning pad, capable of improving comfort ofthe sealing cushion 687 against the user's face (especially when thegranular material 632 in the chamber 630 is in a fixed/rigid or “jammed”state). The softness of the material forming the seal membrane 686 canalso allow the skin contacting region 683 to conform to a user's facialgeometry, despite the thickened nature of the portion 687.

FIG. 20 illustrates yet another variation of the sealing portion 604. Inthis variation of the sealing portion 604, the seal membrane 686 is madewith a foamed material 689. For example, the foamed material 689 can bemade from silicone having air bubbles entrained therein, andpredominantly in the skin contacting region 683. As such, the airbubbles forming the foam structure make the seal membrane 686 a morecompressible and provides a padding function, capable of softening thecontact between the sealing member 686 a and the user's face,particularly when the granular material 632 is in a jammed state. Insome embodiments, the seal membrane 686 a can be manufactured such thatthere are less air bubbles in the inner and outer wall portions 688. Assuch, these portions 688 of the seal membrane 686 a can have a higherstrength and provides more stability at the connection between the sealmembrane 686 a and an associated mask frame 602.

FIG. 21 illustrates yet another variation of the sealing portion 604identified generally by the reference numeral 604 c. In this variationof the sealing portion 604 c, the seal membrane 686 c includes amulti-layered padding assembly 690. The padding layer assembly 690 caninclude a first padding layer 691 and a second padding layer 692.Optionally, a slip region 693 can be disposed between the first layer691 and the second layer 692. As such, the seal membrane 686 c containsseveral layers of different materials. Proximal to the mask frame 602can be a layer of granular material within the chamber 630, and which iscapable of undergoing a jamming transition as described above, when avacuum is applied to the chamber 630. The jamming transition allows thegranular material 632 within the chamber 630 to alternate between aconforming and fixed states. When in the conforming or neutral state,the chamber 630 is able to change shape and conform to the facialgeometry of the user. When in a fixed state, the chamber 630 retains anygeometry that it was adapted to when in the conforming state, andtransitions through the substantially rigid state also referred to as “ajammed state.”

Users may find the feeling of a jammed chamber 630 to be uncomfortablewhen pressed against their face. Thus, the padding layer assembly 690can be configured to provide a softer and more comfortable interfacebetween the chamber 630 and the user's face. As noted above, the paddinglayer assembly 690 can include a first and second layer 691, 692. Insome embodiments, the layers 691 and 692 are filled with gels.

Further, the first gel layer 691 can extend across substantially theentire width W of the sealing portion 604 c. Additionally, the firstlayer 691 can be in a separate sealed chamber or compartment, separatefrom the chamber 630. Additionally, the second layer 692 can also be ina separate chamber separate from the layer 691. In some embodiments, thesecond layer 692 is not attached to the seal membrane 686 c. Thus, insome embodiments, the slip region 693 is disposed between the layer 691and the layer 692. The slip region can be configured to allow the secondlayer 692 to move somewhat independently of the first layer 691. Thisconfiguration can help reduce negative effects of shear forces on theuser's skin; by allowing the layer 691, 692 to slide relative to eachother. Movement of the second layer 692 can cause the region of the sealmembrane 686 c that is proximal to it, to deform and at least partiallyisolate the shear forces existing thereat. The slip region 693 can befilled with a lubricant so as to reduce friction and allow the secondlayer 692 to slide smoothly relative to the first layer 691 and the sealmember 686.

FIGS. 22a, 22b, 22c, and 22d illustrate a further modification of thesealing portion 604 and is identified generally by the referencenumerals 704 a, 704 b, 704 c, and 704 d. Parts, components, and featuresof the sealing portion 704 a, 704 b, 704 c, and 704 d that are the sameor similar to the sealing portion 604 described above are identifiedwith the same reference numerals, except that a value of 100 has beenadded thereto.

The various embodiments of the sealing portion 704 a, 704 b, 704 c, and704 d each include structural reinforcements that affect the deformationof the respective sealing portions. Such structural reinforcements canfurther control how the respective sealing portions to form in use.Controlling the deformation of the sealing portion can be beneficial inproviding an improved seal between a mask and a user's face. Forexample, some variations of the human face can extend along a spectrumof flatter contoured faces and more deeply contoured pointier faces. Assuch, when applying a mask to a flatter face, a better seal may beobtained with the periphery of the mask frame extending along a paththat falls more closely along a plane. However, when applying a mask toa more deeply contoured, pointier face, a particular mask may provide abetter seal if the periphery of the frame of the mask is partiallyfolded in what can be referred to as a “clam shell” configuration. Theclam shell movement and configuration is described in greater detailbelow with reference to FIGS. 23 and 24.

A conformable mask can be provided with more controlled deformation, forexample, to induce a reactionary clam-shelling movement, or resist orbetter accommodate other desirable movements by including structures,for example, within the associated frame and/or seal portion. Theembodiments of FIGS. 22a, 22b, 22c , and 23 include internal structuresthat provide for such functionality.

In some embodiments, the internal structures, which can be in the formof strands, are held in a taught position such that deformation in onelocation translates to movement/deformation in another region. Forexample, deformation caused by pressing the associated mask against thebridge of the nose and thereby compressing the seal will result in thereinforcement strand pulling the sides of the seal inwards towards thenose. This can also be referred to as a clam-shelling movement.

In some embodiments, the strands can have a 3D structure such as a chainlink, a spiral, or other configurations. The surface area provided bysuch structures allows the granular material 732 to apply forces to thestrands that are perpendicular to the length of the strand (i.e., thelongitudinal direction of the seal portion 704). This helps to suspendthe strand in a central position within the seal portion 704, especiallywhen the granular material 732 is in an un-jammed state. The 3Dstructure also allows the strand to be fixed in place more securely whenthe granular material 732 is in a jammed state. The length of the strandcan be pulled through the granular material when the seal portion 704 isdeformed, but the strand should resist coming into contact with the sealmembrane 712 or the mask frame 702. These structures, features andfunctionalities are described in greater detail below with reference toFIGS. 22a -22 d.

Some of these embodiments, generally speaking, include flexible but lesselastic structures that extend along the longitudinal length of theassociated sealing portions. These structural components generatereaction forces that facilitate and guide the deformation of theassociated sealing portions, to greater or lesser degrees. Additionally,these structural reinforcements optionally allow the chamber 730containing granular material 732 which provides a granular jammingfunctionality, to be made from a more elastic material that provides fora better more controllable granular jamming transition, a greater degreeof conformability, but with additional structural reinforcements toprovide some controlled or induced reactionary deformations.

With reference to FIG. 22a , the sealing portion 704 a includes aninternal skeleton 794. In the illustrated embodiment, the internalskeleton 794 is generally a pitchfork shape cross-section member thatextends longitudinally within the seal portion 704 a. Optionally, theinternal skeleton 794 can extend around the entire periphery of anassociated mask frame (not shown) so as to form an annular loop aroundthe entire periphery within the seal portion 704 a.

The outer casing 712, which in this embodiment, forms the chamber 730containing the granular material 732, can be connected to the internalskeleton 794 in various locations. Additionally, the internal skeleton794 is generally open and surrounded by the granular material 732.However, the internal skeleton 794 can constrict movement of thegranular material 732 to some extent within the chamber 730.

The internal skeleton 794 can be constructed by material that is atleast semi-rigid, such that the internal skeleton 794 has someflexibility but substantially maintains its shape when the mask is inuse. Thus, the internal skeleton can guide the seal portion 704 a in aclam-shelling movement, described in greater detail below.

With reference to FIG. 22b , the seal portion 704 b can include aplurality of internal ties 795 at one or a plurality of differentlocations along the thickness T of the seal portion 704 b. In theillustrated embodiment, the seal portion 704 b includes internal ties795 at four different levels along the thickness of the seal 704 b.Additionally, at each level, there are a plurality of internal tiesextending from the inner wall to the outer wall of the seal portion 704b. The internal ties 794 can be configured to be flexible but relativelyinelastic, such that lateral expansion of the seal portion 704 b isrestricted. However, because the internal ties 795 are noncontinuous,the granular material 732 can still move relatively freely within thechamber 730.

With reference to FIG. 22c , the sealing portion 704 c can include oneor more structural layers 796. The structural layers 796 can extendbetween the inner and outer walls of the seal portion 704 c.Additionally, the structural layers 796 can be disposed at differentheights along the thickness T of the sealing portion 704 c and can bespaced from one another with the chamber 730 disposed there between. Thestructural layers 796 can comprise layers of a material that isgenerally more rigid than the material forming the chamber 730. As such,the granular material can flow and thus deform along in the chamber 730to provide an enhanced seal with the user's face. The rigidity providedby the structural layers 796 functions in several ways. For example, thematerial of the structural layers can be the same as that forming thechamber 730, but thicker than the outer walls thereof. As such, theincreased thickness makes the structural layers 796 stiffer.Alternatively, the structural layers 796 can be made from a differentmaterial that is more rigid than that forming the outer surfaces of thechamber 730.

With reference to FIG. 22d , seal portion 704 d can include ridges orbeads 797 extending along the inner and outer walls of the chamber 730.The structural beads 797 can be configured as thickened wall sections ofthe outer casing 712 forming the chamber 730. As in the many otherembodiments, the outer casing 712 can be made from a flexible materialwith elastic properties. However, the bead portion 797, being thickerthan the other portions of the outer casing 712, can provide a higherstiffness than the other portions of the outer casing 712. As such, thestructural beads 797 are less elastic and thus can limit expansion ordeformation of the inner and outer walls of the seal portion 704 d.Optionally, the beads 797 can form a continuous structure or loop aroundthe length of the seal portion 704 b. Optionally, the beads 797 can bemade of thin metal wires or rigid plastics such as polycarbonate orother materials. In some embodiments, the beads 797 can have a diameterof about 0.1-5 mm.

With reference to FIGS. 23 and 24, the clam-shelling movementsreferenced above are illustrated therein. With reference to FIG. 23, amask 100 can be applied to a user face that is generally flatter. Thus,the mask 100 can be deformed by pulling the side walls laterallyoutwardly, for example, in the direction of arrows 2000 and 2002. Assuch, the frame 102 becomes wider in the direction of dimension S, andshorter in height along the dimension H. The structural reinforcementsdescribed above with regard to the seal portions 704 a-704 d, can causereactionary forces that tend to cause the deformation of the seal 104,in a clam shelling movement, to better follow the deformation of theframe 102, so as to reduce the total height H of the seal 102. Forexample, the reactionary forces, generated by the structuralreinforcements described above, cause reactionary forces in thedirection of arrows 2004, 2006 on the seal. Additionally, the structuralreinforcements can help prevent the seal portion 704 b from being“necked” (squeezed into an excessively thin shape) by helping tomaintain the desired shape of the seal 104 and optionally the locationof the granular material. If excessive necking occurs, the stiffeningfunction of the granular jamming-enabled portions of the seals can bereduced.

By contrast, with reference to FIG. 24, when the mask 100 is applied toa user's face with deeper contours and a more pointy configuration, auser may attempt to squeeze the side walls of the mask 100 inwardly, inthe direction of arrows 2008, 2010. This squeezing motion causesreactionary forces, which can be at least partially due to thestructural reinforcements described above with reference to sealportions 704 a-704 d, in the direction of arrows 2012, 2014 which tendto increase the overall height H of the frame 102 and seal portion 104.

Optionally, as described above with reference to FIGS. 4a -4 c, the mask100 can include one or more flexible portions 109, 111 which can beconfigured and/or oriented to enhance the ease of the above-describedclam-shelling movement.

An aspect of at least one of the embodiments disclosed herein includesthe realization that this clam-shelling movement can assist a user inattempting to fit a mask 100 onto different user faces.

With reference to FIGS. 24a and 24b , the mask 100 can also be providedwith optional features configured for better accommodating movements ofa patient, including after the mask 100 has been fitted onto their face,and optionally, after a variable stiffness portion of the mask has beentransitioned to a stiffer state. For example, with reference to FIG. 24a, the seal portion 104 can include a variable stiffness portion that hasdifferent characteristics along its peripheral length L.

For example, with reference to FIG. 24a , the seal 104 can be consideredas including an upper portion 104 a, a lower portion 104 b, andintermediary portions 104 c, 104 d disposed on the left and right sidesof the seal 104 and between the upper and lower portions 104 a, 104 b.Optionally, the intermediary portions 104 c, 104 d can be configured tohave different mechanical characteristics relative to the upper andlower portions 104 a, 104 b. For example, such differential mechanicalcharacteristics can be provided by different thicknesses of materials,different material types, and/or different material configurations. Insome embodiments, the upper and lower portions 104 a, 104 b can includegranular jamming chambers including granules made from a hardermaterial. By contrast, the intermediary portions 104 c, 104 d caninclude granular jamming portions including softer granular material,for example, material that is more elastic and less stiff than thegranular material in the upper and lower portions 104 a, 104 b.

Optionally, the chambers forming the upper portion 104 a, lower portion104 b, and intermediary portions 104 c, 104 d can be formed from asingle chamber configured for variable stiffness such as operation underthe granular jamming principle of operation described above, or otherconfigurations. Optionally, in a single chamber configuration, dividerscan be included between the various different portions 104 a, 104 b, 104c, 104 d so as to maintain the stiffer and softer granules in thedesired locations. Further, optionally, the portions 104 a, 104 b, 104c, 104 d can be made from separate chambers positioned proximate orjuxtaposed to one another, in the arrangement illustrated in FIG. 24a ,however, other configurations can also be used.

In any of the above or other configurations, the seal portion 104 can beconfigured to provide for enhanced flexibility in the areas of theintermediate portions 104 c, 104 d, for example, as noted above, withthe use of softer, or more elastic granular material in the intermediaryportions 104 c, 104 d. Optionally, these intermediary portions 104 c,104 d can be configured to be more deformable even when in a state ofincreases stiffness or a “jammed state.” Such additional deformabilitycan allow these regions to be elongated in the direction of the arrow Eof FIG. 24a so as to better accommodate movement of the jaw of a user.Further, optionally, the intermediary portions 104 c, 104 d and/or theupper and lower portions 104 a, 104 d can include elastic casingsforming the chambers containing the granules.

As such, and optionally in addition to using softer or more elasticgranular material in the intermediary portions 104 c, 104 d, the seal104 can allow for stretching in the direction of arrow E and elasticreturn to the same or substantially the same shape before suchstretching in the elongation direction E. During stretching along thedirection E, some necking can occur in the granular material in theportions 104 a, 104 b, 104 c, 104 d as such regions are elongated. Suchnecking can substantially or completely disappear when the force appliedto the seal 104 causing elongation in the direction of arrow E isreleased. Such elastic return can be accommodated by the softer or moreelastic granules included the intermediary portions, 104 c, 104 d whilemaintaining the same arrangement in relation to each other, for example,while in a jammed state. In comparison, if necking occurs in a region,for example, the upper and lower portions 104 a, 104 b in which hardgranular materials are used, such necking may not return to the originalstate because such necking can be associated with actual flow ormovement of the granules, relative to each other, rather than elasticdeformation of the granules.

With reference to FIG. 24b , additional beneficial jaw movementaccommodation can also be achieved by providing additional flexibleportions to the mask 100, such as in the frame portion 102. Optionally,the frame 102 can include a flexible portion, such as the flexibleportion 111, described in greater detail above with reference to FIG. 4a. Optionally, with continued reference to FIG. 24b , the flexibleportion 111 can be in the form of bellows, which allow the frame 102 toexpand along with the expansion of the seal portion 104, as describedabove in the elongation direction E. Such bellows can be made from anadditional member made from a flexible material, such as silicone,attaching two parts of the frame 102 together. In the form of a hinge orexpandable bellows, the flexible portion 111 can allow the frame portion102 to better accommodate patient movements, such as jaw movements, evenafter portions of the seal or other portions of the mask have beentransitioned to a higher stiffness state, such as under the granularjamming principle of operation, or other techniques.

With reference to FIG. 24c , the mask 100 can also include optionalfeatures to further accommodate movements of a user's face during use ofthe mask and/or during fitting of the mask 100. For example, withreference to the cross-sectional view of FIG. 24, when portions of theframe are moving inward or outwardly, for example, in the direction ofarrows 2000, 2002, 2008, 2010 of FIGS. 23 and 24, and optionally aboutflexible portion 109, the seal 104 can move relative to a patient'sface. Thus, in some optional embodiments, portions or all of theconnection between the frame 102 and the seal 104 can include additionalflexibility to allow, enhance, or increase an additional flexibility ormovement of the seal 104 relative to the frame 102.

For example, as shown in FIG. 24c , movement of portions of the framesalong the arrows P, which may be considered as a pivoting direction ofmovement relative to the flexible portion 109, the seal portion 104 canroll along a surface of the patient, through arcs identified by thearrows R in FIG. 24c . Thus, the mask 100 can optionally include one ormore flexible connectors 102 a connecting the frame to the seal 104. Theflexible connector 102 a can be in the form of a flexible portion of theframe 102, a separate flexible device interposed between the frame 102and the seal 104 and/or by the configuration of the portion of the seal104 connected to the frame 102, for example, where only a thin or narrowarea of the seal 104 is attached directly to the frame 102. Otherconfigurations can also be used. In some embodiments, the flexibleconnections 102 a are configured to allow the seal 104 to roll relativeto the frame 102 with relatively little force, for example, through arange of rolling angles represented by the angle 102 b of FIG. 24c withvery little force, for example, one or a few newtons. However, otherstiffnesses could be used which would generate other ranges of movementunder different ranges of forces applied.

With reference to FIG. 25, another modification of the seal portion 704is illustrated therein and identified generally by the reference numeral804. Parts, components, and features of the seal portion 704 areidentified with the same reference numerals except that a value of 100has been added thereto.

The seal portion 804 illustrated in FIG. 25 is configured to containseparated layers of different types of granular material. Generally, thegranular material included in the various embodiments disclosed hereincan be a suitable biocompatible material. The physical attributes,however, of the granular material can be selected to provide a range ofdifferent jamming characteristics and conformance properties. Thus, anyof the embodiments disclosed herein can include any granular material,including those described as follows:

-   -   Variable size, wherein the granular material contains a range of        granule sizes. This may enable improved jamming between the        granules.    -   Breathability, wherein the granular material is breathable and        allows excess water vapor to escape.    -   Spherical geometry, wherein each of the granules is spherical.        This may improve user comfort by minimizing contact with sharp        edges or corners.    -   Polyhedral geometry, wherein each of the granules has a number        of flat surfaces and corners. In some materials the corners may        be rounded.    -   Variable geometry, wherein the granular material contains        granules of a variety of geometries.    -   Composite material, wherein the granules may be of a variety of        differing materials that provide specific physical attributes in        combination.    -   Compressibility, wherein the granules may be compressible,        incompressible, or may be mixed with both compressible and        incompressible granules together in the same granular jamming        chamber. This may provide a softer and more conformable mask        seal. In some embodiments, some or all of the compressible        granules may contain air, which may make the mask lighter to        wear.    -   Thermal conductivity, wherein the granular material can be        thermally conductive, thermally non-conductive or a mixture of        both thermally conductive and non-conductive granules together        in the same granular jamming chamber so as to allow the desired        thermoregulation of the user's skin. This may improve user        comfort and compliance.

With continued reference to FIG. 25, the seal portion 804 can include aplurality of layers of a plurality of different granular materials. Thegranular materials can configured to contain different sized granules ineach layer or other different characteristics.

As shown in FIG. 25, the seal portion 804 includes a granular jammingchamber 830 divided into three layers; a first layer 900, a second layer902 and a third layer 904.

The three layers 900, 902, 904 of the chamber 830, in some embodiments,each contain granular materials of different size. For example, thefirst layer 900 of the chamber 830 can include micro-sized granules. Thesecond layer 902 can comprise granules that are larger than the firstgranular material. Similarly, the third layer 904 can include granulesthat are a macro-size and larger than the second granular material. Thelayers 900, 902, 904 of granular material can be separated by screens.For example, the first and second layers 900, 902 can be separated byscreen 906 and the second layer 902 and the third layer 904 can beseparated by screen 908. The screens 906, 908 are configured to preventpassage of any of the granular material between the various layers 900,902, 904, but 5 are also configured to allow a suspension fluid 936,such as air or another gas, to pass there through.

In some embodiments, the first layer 900 containing micro-sized granulesis configured to be adjacent to the sealing surface 885. Thisconfiguration can be advantageous in providing a more “high-definition”conformance between the seal 885 and the user's face. The micro-sizedgranules can more closely match facial geometries as a result of therebeing less space between the granules when in a jammed state. Thediffering granule size in each layer 900, 902, 904, can provide variablerigidity and structure to the seal portion 804. Additionally, in someembodiments, the screens 906, 908 can provide some structuralreinforcement characteristics, similar to those provided in the sealportion 704 a-704 d described above.

FIGS. 26a-29b illustrate four additional modifications of the sealsdescribed above, each of which include an inflatable bladder.Additionally, the illustrations of FIGS. 26a-29b reflect only a partialcross-section of the seal member that can be used with any of the masksdescribed above or masks or portions of masks described below, forexample, the masks including a frame such as that partially illustratedin FIGS. 30-35 below.

With reference to FIGS. 26a, 26b , a seal 3004 can compromise amulti-layered design including a variable stiffness portion, which canbe in the form of granular jamming chamber 3030, a comfort layer 3091,which can comprise any type of more compressible comfortable materialsor configurations such as silicone, foam, gel material or othermaterials. Additionally, the seal 3004 can include an inflatable portion3050 disposed between the variable stiffness portion 3030 and thecomfort layer 3091.

The variable stiffness portion 3030 can be in the form of any of thevariations of granular jamming enabled seal portions described above,including multi-layers, variable sizes and hardnesses of granularmaterial, stiffening components, etc. The variable stiffness portion3030, the inflatable bladder 3050, and the comfort layer 3091, can beindividually encased in material forming three independent chambers,however, they can also share common walls. In some embodiments, thewalls of these portions 3030, 3050, 3091 can be made from thin, soft,elastic or nonelastic materials as desired, including silicone, andother materials described above.

FIG. 26a illustrates the seal 3004 in a deflated state. As shown in FIG.26a , the comfort layer 3091 has a thickness 3092 in its relaxed stateand when the seal inflatable portion 3050 is deflated. Additionally, thecomfort layer 3091 includes end walls 3094, 3096 at the inner and outeredges of the seal 3004. The inner and outer ends of the comfort layer3092 are attached to the remaining portions of the seal 3004, forexample, the variable stiffness portion 3030, at relatively smallcontact areas.

With reference to FIG. 26b , when the inflatable portion 3050 isinflated, for example, when the variable stiffness portion 3030 isoptionally in a state of higher stiffness, fluid added into theinflatable portion 3050, such as a liquid or a gas, causes the comfortlayer 3091 to deflect away from the variable stiffness portion 3030which can provide the additional optional benefit of changing thecharacteristic and potentially increasing the amount of surface contactbetween the comfort layer 3091 and a patient. In some embodiments, theseal 3004 can include a valve 3052 for inflating and deflating theinflatable portion 3050. Such a change in shape of the comfort layer3091 relative to the relatively stiffer portion 3030, caused byinflation of the inflatable portion 3050, can thus help reduce oreliminate leaks.

The shape of the comfort layer 3091 and the manner in which it isconnected to the relatively stiffer portion 3030 can affect the way thecomfort layer 3091 expands as the inflatable portion 3050 is inflated.For example, if the comfort layer 3091 is a substantially uniformthickness along and/or around the inflatable bladder, the inflatableportion 3050 and the comfort layer 3091 can expand in a direction thatis substantially perpendicular to the stiffer portion 3030. As shown inFIGS. 26a and 26b , the inflatable portion 3050 has a substantially flatcross-section. Thus, when inflated, the inflatable portion 3050 and thecomfort layer 3091 also tend to have a generally flat profile, which canenhance or provide increased contact area with the patient, such as withthe patient's face.

With reference to FIGS. 27a and 27b , a seal 3100 can include a morerounded comfort layer 3191 when the seal 3100 is in a relaxed state, asshown by comparison of FIG. 27a and FIG. 26a . For example, withcontinued reference to FIG. 27a , the comfort layer 3191 can have itsends 3194, 3196 connected to a lower surface of the relatively stifferportion 3130. This provides the comfort layer 3191 with a generally morerounded configuration.

Thus, with continued reference to FIG. 27b , when the inflatable portion3150 is inflated, the inflatable portion 3150 becomes more rounded aswell as the outer surface of the comfort layer 3191, which can provide adifferent sealing characteristic when the inflatable portion 3150 isinflated, for example, providing a more rounded outer sealing surface ofthe seal 3100 which may provide less contact with certain portions of auser's face or more contact with different portions of a user's face.

FIGS. 28a and 28b illustrate yet another modification of the seal 3004,identified generally by the reference numeral 3204. As illustrated inFIGS. 28a, 28b , the seal 3204 includes bellows 3252 disposed in sidewalls of the inflatable portion 3250 to provide a different manner inwhich the inflatable portion 3250 inflates and thus deforms duringinflation. For example, the bellows 3252 can be made from asubstantially inelastic material, in a folded position when theinflatable portion 3250 is deflated and thus unfold and allow expansionof the side walls in a more linear direction during inflation of theinflatable portion 3250. Such use of bellows or other devices can resultin a more unidirectional expansion of the inflatable portion 3250 andthe comfort layer 3291. As such, the comfort layer 3291 can expandtowards a patient and generate a larger contact area with the patientand/or increased sealing pressure against a patient.

With reference to FIGS. 29a and 29b , yet another modification of theseal 3004, identified generally by the reference numeral 3304. In such aconfiguration, the seal 3304 includes an inflatable portion 3350 butwith no additional thickened comfort layer. Rather, the inflatableportion 3350 can be formed of a thin sheet material, such as silicone orother materials, and can be inflated on demand, for example, using avalve such as the valve 3052 noted above. As such, the inflatableportion 3350 can be inflated after the generally stiffer portion 3330 isconfigured into the desired shape. Then, upon inflation, the inflatableportion 3350 can provide enhanced contact with the patient's face, anddue to the configuration of the outer wall 3384, can more readily adaptto finer features of a patient, such as creases, recesses, or folds in apatient's skin so as to provide a better seal with less contactpressure.

In some embodiments, a mask can be provided with the seal 3304 and theinflatable portion 3350 in a permanently inflated state. As such, such amask is further simplified, easier to use, and potentially with lowermanufacturing costs. Using a sufficiently elastic outer wall 3384, thebladder 3350 can remain inflated during the process of reshaping therelatively stiffer portion 3330. Then after shaping the relativelystiffer portion 3330 into the desired shape, the inflatable portion 3350would elastically reshape itself, under the force of the fluid containedtherein and the elastic behavior or elastic characteristic of the outerwall 3384 and can thus enhance a seal between the relatively stifferportion 3330 and a patient.

FIGS. 30-35 illustrate an optional process for using a mask with theseal 3004, although the description of FIGS. 30-35 would also apply tothe use of any of the other seals described above.

FIG. 30 illustrates a mask having a frame 3002 which can be a generallystiff portion of an associated mask. For example, in some embodiments,the frame 3002 is made of polycarbonate or other generally stiffmaterials. Optionally, as shown in FIG. 30, the frame 3002 can include askirt portion 3002 a which can be generally less stiff or more flexiblethan the frame 3002. For example, in some embodiments, the skirt 3002 acan be formed of silicone. The skirt 3102 a is connected to the seal3004. In the illustrated embodiment, the skirt 3002 a is connected to anouter edge of the seal 3004.

In the orientation illustrated in FIG. 30, the seal 3004 is spaced awayfrom the patient. During the process of fitting the mask to a patient,the seal 3004 can be brought into contact with a patient, as shown inFIG. 31.

With reference to FIG. 32, the mask can be pushed against the patient soas to cause some deformation of the outer surface of the seal 3004 forexample, including the outer surface of the comfort layer 3091, and insome uses, deformation of the portion 3030. In embodiments where theportion 3030 is a variable stiffness portion, operating under theprinciple of granular jamming for example, the portion 3030 can deformto better follow contours of a patient when in its neutral or areduced-stiffness state. Further, in some embodiments, the comfort layer3091 can be configured to be less stiff than the stiffness of theportion 3030. For example, in some embodiments, the comfort layer 3091can be configured to be less stiff than the stiffness of the portion3030 when the portion 3030 is in a neutral state, or optionally, whenthe portion 3030 is in an intermediate stiffness state that is lessstiff than the stiffness of the portion 3030 when in a maximum stiffnessstate. As such, the portion 3030 can conform to the geometry of thetarget portion of the patient, such as the patient's face, without thecomfort layer 3091 deforming to an extent that would reduce conformanceof the comfort layer 3091 to the target portion of the patient.Additionally, in an embodiment the comfort layer 3091 does not restrictthe ability of the portion 3030 to conform to the target portion of thepatient when the portion 3030 is in its neutral or a reduced-stiffnessstate.

With reference to FIG. 33, with the portion 3030 deformed from itsrelaxed shape, the portion 3030 can be transitioned to a higher state ofgreater stiffness, for example, by subjecting the portion 3030 to avacuum so as to achieve a state of higher stiffness through granularjamming. This transition is illustrated in FIG. 33 by the deformation ofthe outer casing of the portion 3030 into a tighter fitting engagementof the granules within the portion 3030. At this point, the portion 3030is now relatively stiffer and deformed from its relaxed stateillustrated in FIG. 30.

With reference to FIG. 34, with the portion 3030 still in a state ofheightened stiffness, the inflatable portion 3050 can be inflated. Forexample, but without limitation, a fluid such as a gas or a liquid,including but without limitation, air. As such, the outer surface of thecomfort layer 3091 is urged away from the relatively stiffer portion3030 into greater contact with the patient. As such, the comfort layer3091 can further expand into small creases, folds, or recesses of theuser's face and thereby achieve a better seal using lower tensions andstraps for attaching the mask to a patient. The additional forcesprovided by the inflatable portion 3050 can also apply small forces to auser's face resulting in some creases being smoothed. Finally, theexpansion of the inflatable portion 3050 can increase the surface areaof the comfort layer 3091 in contact with the user's face therebyincreasing the likelihood that a seal can be generated around a crease,fold, or recess which may have caused a leak or leak zone.

Generally, a fluid filled inflatable portion 3050 will expand along thepath of least resistance when expanding under positive pressure. Thiscan result in the inflatable portion 3050 expanding away from therelatively stiffer portion 3030 and into any gaps between the patient'sskin and the sealing surface of the comfort layer 3091. By expanding inthis way, the comfort layer 3091 can be pushed into and at leastpartially fill gaps between the comfort layer and the patient's face.For example, as shown in FIG. 36, the outer surface of the comfort layer3091 can expand into the recess 46 (also described above with referenceto FIG. 2b ).

With reference to FIG. 35, in some embodiments, the fluid from withinthe inflatable portion 350 can be released, allowing the seal 3004 toreturn to its neutral state.

The granular jamming chambers of the embodiments of the masks disclosedabove can be connected to any type of vacuum device for the purpose oftransitioning to the jammed state. For example, such a vacuum device canbe used to initiate the jamming phase within the masks disclosed hereinby reducing the pressure within the conforming seal and/or frame. Avacuum can be supplied to the mask in a number of ways, including butnot limited to a dedicated vacuum pump, hospital suction lines, or asyringe.

A vacuum supply may not always be readily accessible in the environmentin which the mask of the present disclosure is to be used. It is,however, more likely that there will be a positive pressure sourceavailable, since it is required to provide therapy via the mask. It maytherefore be advantageous to be able to generate a vacuum supply from apositive pressure source.

With reference to FIGS. 37 and 38, one non-limiting exemplary embodimentof a vacuum supply 4000, which can convert positive pressure to negativepressure, is shown in FIGS. 37 and 38. FIG. 37 shows the device 4000comprising a pressure source 4002, first and second chambers 4004, 4006,first and second plungers 4008, 4010, a coupler 4012, and a vacuumconnection 4014. The pressure source 4002 may be any suitable supply ofpressurized fluid, such as but not limited to flow generator,ventilators or pressurized gas lines. In FIG. 37, the device 4000 isshown in a substantially neutral state without a pressure being appliedby the pressure source.

The first chamber 4004 can comprise a high pressure connection 4016,which is configured to connect to the pressure source 4002. The secondchamber 4006 comprises a low pressure/vacuum connection 4014, configuredto connect to a mask connection 4018; wherein the mask connection 4018is configured to connect to a mask, such as the mask 100 or any of themasks described above. The first and second chambers 4004, 4006 may beconfigured to house the first and second plungers, 4008, 4010,respectively.

The first and second plungers 4008, 4010 can comprise seals 4020, 4022,respectively, and first and second plunger columns 4024, 4026. The firstand second plunger columns 4024, 4026 are configured to be connected bythe coupler 4012, such that the movement of one plunger (e.g., 4008)will result in movement of the other plunger (e.g., 4010).

The configuration of the device 4000, as described herein, allows theapplication of a positive pressure in the first chamber 4004 to beconverted to a negative pressure, or vacuum, in the second chamber 4006.

FIG. 38 shows the device 4000, of the present description, with apositive pressure applied to the first chamber 4004. The positivepressure provided by the pressure source 4002 applies a force to thefirst plunger 4008 causing it to translate along the chamber 4004. Themovement of the first plunger 4008 causes the first and second plungercolumns 4024, 4026, linked by the coupler 4012, to move the secondplunger 4010, inducing a negative pressure or vacuum within the secondchamber 4006. The vacuum can be applied to the mask 100 via the lowpressure/vacuum connection 4014 and mask connection 4018, such that ajamming transition phase is induced in the variable stiffness portionincluded in a seal and/or frame of the mask 100.

FIGS. 39 and 40 illustrate a modification of the mask 4000, identifiedgenerally by the reference numeral 5000. Parts, components, and featuresof the device 5000 that are the same, or can be substantially the sameas the components of the device 4000 are identified with the samereference numeral, except that 1000 has been added thereto.

In the device 5000, the first and second chambers 5004, 5006 are ofdifferent sizes in order to provide a step up or step down in thepressure ratio between the chambers 5004, 5006. Correspondingly, thefirst and second plungers 5008, 5010 and respective seals 5020, 5022 aresized to match the size of the respective chamber 5004, 5006. As shownin FIG. 39, the first chamber 5004 is smaller than the second chamber5006. This may result in a large positive pressure being converted intoa smaller negative pressure in the second chamber 5006. Alternatively,as depicted in the modification of FIG. 40, identified by the referencenumeral 6000, the first chamber 6004 can be larger than the secondchamber 6006. Such a differential sizing of the chamber 6004, 6006 canresult in the application of a small positive pressure in chamber 6004being converted into a larger negative pressure in chamber 6006.

FIG. 41 includes a flow chart illustrating a method that can be used forfitting any of the above-described masks to a patient, including maskshaving inflatable portions. With reference to the flow chart 7000 ofFIG. 41, the method can begin with operation block 7002.

In operation block 7002, the method 7000 can begin, with the mask 100 ina neutral state. For example, the mask 100 can be considered to be in aneutral state if the mask includes a variable stiffness portion, and thevariable stiffness portion is in a state of lower stiffness. If thevariable stiffness portion is in the form of a granular jamming portion,then the granular jamming portion would be considered to be in a neutralstate if the granules are not compressed into a jammed state, and thuscan flow, for example, viscously, within the chamber. Additionally, ifthe mask includes an inflatable portion, then the inflatable portionwould be considered to be in a neutral state if the inflatable portionis deflated, collapsed, at atmospheric pressure or under a vacuum. Afterthe operation block 7002, the method 7000 can move onto operation block7004.

In the operation block 7004, the mask can be applied to a patient'sface. For example, the mask 100 can be pushed against a patient's faceby the patient or healthcare worker. Additionally, the mask, such as theseal portion 104 and/or the frame portion 102 can be deformed to betterconform to a patient's face. Additionally, the deformation of the sealportion can include deformation of a variable stiffness portion, such asa granular jamming portion, an inflatable portion, a gel or comfortlayer, etc. After the operation block 7004, the method 7000 can move onto the operation block 7006.

In the operation block 7006, the deformed state of the mask can bepreserved. For example, if the mask includes a variable stiffnessportion, the variable stiffness portion can be transitioned to a higherstiffness state. If the variable stiffness portion is a granular jammingenabled portion, then the granular jamming enabled portion can besubject to a vacuum to cause the granular jamming enabled portion toincrease in viscosity and/or to be otherwise transitioned to a higherstiffness state, which in some embodiments, can be a “jammed” state. Insome embodiments, such transitioned state of a variable stiffnessportion or a granular jamming enabled portion can be considered asforming a relatively stiffer portion of a seal or mask. After theoperation block 7006, the method 7000 can move onto operation block7008.

In operation block 7008, the mask can optionally be secured to apatient's head with headgear, such as straps. Additionally, air under apositive pressure, can be supplied to a patient's airways through themask. After the operation block 7008, the method 7000 can move on tooperation block 7010.

In operation block 7010, leaks of the mask can be detected. For example,the patient or healthcare worker can probe the areas around the vicinityof a seal of the mask to determine if a positive pressure flow of aircan be detected. After the operation block 7010, the method 7000 canmove on to operation block 7012.

In the operation block 7012, a portion of the seal can be expanded. Forexample, if the mask includes an inflatable portion, the inflatableportion can be expanded. In some embodiments, the inflatable portion canbe disposed between a relatively stiffer portion, such as a variablestiffness portion in a state of heightened stiffness, or a granularjamming portion which has been transitioned toward a jamming state. Insome embodiments, the inflatable portion can be provided with positivefluid pressure, such as positive pressure of gas, to thereby inflate theinflatable portion. Optionally, the inflatable portion can be inflateduntil any detected leaks have been reduced to an acceptable amount oreliminated. Other techniques can also be used.

A number of examples of therapeutic fluid delivery device aspects of theinterfaces, and variations on each aspect, have been discussed withreference to other Figures. The present application contemplates that atherapeutic fluid delivery device may incorporate some aspects but notother aspects. For example, a therapeutic fluid delivery device mightincorporate aspects of a mask while using a different arrangement forsecuring the mask to the user. All of these variations are consideredwithin the scope of this application.

Although the inventions disclosed herein are described in the context ofcertain preferred embodiments and examples, it will be understood bythose skilled in the art that the present inventions extend beyond thespecifically disclosed embodiments to other alternative embodimentsand/or uses of the inventions and obvious modifications and equivalentsthereof. In addition, while several variations of the inventions havebeen shown and described in detail, other modifications, which arewithin the scope of these inventions, will be readily apparent to thoseof skill in the art based upon this disclosure. It is also contemplatedthat various combination or sub-combinations of the specific featuresand aspects of the embodiments can be made and still fall within thescope of the inventions. It should be understood that various featuresand aspects of the disclosed embodiments can be combined with orsubstituted for one another in order to form varying modes of thedisclosed inventions. Thus, it is intended that the scope of at leastsome of the present inventions herein disclosed should not be limited bythe particular disclosed embodiments described above.

1. A respiratory mask configured to fit a plurality ofdifferently-shaped human faces, comprising: a frame portion comprising aperimeter portion and a conduit connection portion; a seal portionconnected to the perimeter portion of the frame portion, the sealportion comprising a sealing surface and a connecting surface, theconnecting surface being connected to the perimeter portion, the sealingsurface configured to form a seal with a portion of a human face; atleast one of the frame portion and the seal portion comprising avariable stiffness portion configured to selectively transition betweena decreased stiffness state and an increased stiffness state wherein thevariable stiffness portion comprises a density-dependent, variableviscosity material contained in a compressible chamber.
 2. (canceled) 3.The respiratory mask according to claim 1, wherein thedensity-dependent, variable viscosity material is a granular material.4. The respiratory mask according to claim 1, wherein the compressiblechamber is an air-tight bladder and contains a granular material and isconfigured to maintain a vacuum therein and so as to collapse againstthe granular material, increase a density thereof and thereby increase aviscosity of the granular material therein and transition the variablestiffness portion to the increased stiffness state.
 5. The respiratorymask according to claim 4, additionally comprising a releasable one-wayvalve mounted to the air-tight bladder.
 6. The respiratory maskaccording to claim 1, wherein the variable stiffness portion is includedin the seal portion, the variable stiffness portion defining at leastabout 60-80% of the seal portion.
 7. The respiratory mask according toclaim 1, wherein the variable stiffness portion is included in the sealportion, and the variable stiffness portion extends across substantiallyan entire width of the seal portion.
 8. The respiratory mask accordingto claim 1, wherein the variable stiffness portion is included in theseal portion and defines a layer of the seal portion.
 9. The respiratorymask according to claim 1, wherein the variable stiffness portioncomprises a plurality of variable stiffness layers, the plurality ofvariable stiffness layers comprising at least first and second granularjamming chambers.
 10. The respiratory mask according to claim 9, whereinthe first granular jamming chamber comprises first granules and thesecond granular jamming chamber comprises second granules, the firstgranules being different from the second granules.
 11. The respiratorymask according to claim 1, wherein the variable stiffness portion isdisposed in the seal portion between the perimeter portion of the frameportion and the sealing surface of the seal portion, the respiratorymask additionally comprising a cushion portion disposed between thevariable stiffness portion and the sealing surface.
 12. The respiratorymask according to claim 11, wherein the variable stiffness portioncomprises a granular jamming chamber and wherein the cushion portioncomprises a gel.
 13. The respiratory mask according to claim 1, whereinthe seal portion comprises at least one reinforcement strand extendingalong at least a portion of a length of the seal portion.
 14. Therespiratory mask according to claim 13, wherein the at least onereinforcement strand extends along the entire length of the sealportion, forming a loop.
 15. The respiratory mask according to claim 1,wherein the frame portion comprises a seal support portion connected tothe seal portion and is configured to be deformable through aclam-shelling movement.
 16. The respiratory mask according to claim 15,wherein the portion frame comprises at least first and second frameportions and at least a first flexible portion connecting the first andsecond frame portions and configured to allow the first and second frameportions to be moved relative to one another in the clam-shellingmovement, wherein the first flexible portion comprises the variablestiffness portion, wherein the variable stiffness portion is configuredto be selectively transitionable between a first more flexible state anda second less flexible state, wherein the variable stiffness portioncomprises a granular jamming chamber.
 17. The respiratory mask accordingto claim 16, wherein the first and second frame portions are stifferthan the seal portion and wherein the first and second frame portionsdefine at least a portion of the seal support portion.
 18. Therespiratory mask according to claim 1, wherein the seal portioncomprises an inflatable bladder disposed between the sealing surface andthe connecting surface.
 19. (canceled)
 20. (canceled)
 21. (canceled) 22.(canceled)
 23. (canceled)
 24. (canceled)
 25. (canceled)
 26. (canceled)27. (canceled)
 28. (canceled)
 29. (canceled)
 30. (canceled) 31.(canceled)
 32. (canceled)
 33. A respiratory mask configured to fit aplurality of differently-shaped human faces, comprising: a frame portioncomprising a perimeter portion and a conduit connection portion; a sealportion connected to the perimeter portion of the frame portion, theseal portion comprising a sealing surface and a connecting surface, theconnecting surface being connected to the perimeter portion, the sealingsurface configured to form a seal with a portion of a human face, theseal portion comprising a layer of granular material and an inflatablebladder, the layer of granular material being disposed between the frameportion and the inflatable bladder.
 34. (canceled)
 35. (canceled) 36.(canceled)
 37. A respiratory mask configured to fit a plurality ofdifferently-shaped human faces, comprising: a frame portion comprising aperimeter portion and a conduit connection portion; a seal portionconnected to the perimeter portion of the frame portion, the sealportion comprising a sealing surface and a connecting surface, theconnecting surface being connected to the perimeter portion, the sealingsurface configured to form a seal with a portion of a human face; atleast one of the frame portion and the seal portion comprising agranular chamber comprising a plurality of granules.
 38. (canceled)